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Full text of "Zebra Z4000-Z6000 User Manual"

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Z Series 

User's Guide 



For the Zebra Z4000™ and Z6000™ Printers 




Customer order # 77460L Manufacturer part # 77460LB Rev. 2 



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Proprietary Statement 

This manual contains proprietary information of Zebra Technologies Corporation. It is in- 
tended solely for the information and use of parties operating andmaintaining the equip- 
ment described herein. Such proprietary information may not be used, reproduced, or 
disclosed to any other parties for any other purpose without the expressed written permis- 
sion of Zebra Technologies Corporation. 

Product Improvements 

Continuous improvement of products is a policy of Zebra Technologies Corporation. All 
specifications and signs are subject to change without notice. 

FCC Compliance Statement 

NOTE: This equipment has been tested and found to comply with the limits for a Class B 
digital device, pursuant to Part 1 5 of the FCC Rules. These limits are designed to provide 
reasonable protection against harmful interference in a residential installation. This 
equipment generates, uses and can radiate radio frequency energy and, if not installed and 
used in accordance with the instructions, may cause harmful interference to radio com- 
munications. However, there is no guarantee that the interference will not occur in a par- 
ticular installation. If this equipment does cause harmful interference to radio or 
television reception, which can be determined by turning the equipment off and on, the 
user is encouraged to try to correct the interference by one or more of the following 
measures: 

■ Reorient or relocate the receiving antenna. 

■ Increase the separation between the equipment and the receiver. 

■ Connect the equipment into an outlet on a circuit different from that to which the 
receiver is connected. 

■ Consult the dealer or an experienced Radio/TV technician for help. 

NOTE: This unit was tested with shielded cables on the peripheral devices. Shielded 
cables must be used with the unit to insure compliance. 

"The user is cautioned that any changes or modifications not expressly approved by Zebra 
Technologies Corporation could void the user's authority to operate the equipment." 

Canadian DOC Compliance Statement 

This digital apparatus does not exceed the Class A limits for radio noise emissions from 
digital apparatus as set out in the radio interference regulations of the Canadian Depart- 
ment of Communications. 

Liability Disclaimer 

Zebra Technologies Corporation takes steps to assure that its published Engineering 
Specifications and Manuals are correct; however, errors do occur. Zebra Technologies 
Corpora tion reserves the right to correct any such errors and disclaims liability resulting 
therefrom. 

No Liability for Consequential Damage 

In no event shall Zebra Technologies corporation or anyone else involved in the creation, 

E reduction, or delivery of the accompanying product (including hardware and software) 
e liable for any damages whatsoever (including, without limitation, damages for loss of 
business profits, business interruption, loss of business information, or other pecuniary 
loss) arising out of the use of or the results of use of or inability to use such product, even 
if Zebra Technologies Corporation has been advised of the possibility of such damages. 
Because some states do not allow the exclusion or limitation of liability for consequential 
or incidental damages, the above limitation may not apply to you. 

Copyrights 

This copyrighted manual and the label printers described herein are owned by Zebra Tech- 
nologies Corporation. All rights are reserved. Unauthorized reproduction of this manual or 
the software in the label printer may result in imprisonment of up to one year and fines of 
up to $10,000 (1 7 U.S.C506). Copyright violators may be subject to civil liability. 



IBM* is a, registered trademark of IBM Corporation. 
Goo Qone * is a Registered Trademark of Magic American Corporation 
Zebra*, Stripe*, ZPL*, and ZPL II* are registered trademarks, and Z Series, 
Z4000, and Z6000 are trademarks of Zebra Technologies Corporation. 

© Zebra Technologies Corporation 



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DECLARATION 0¥ CONFORMITY 



I have determined that the Zebra printers identified as the 

Z Series™ Z4000™ 

& 
Z Series™ Z6000™ 

manufactured by: 

Zebra Technologies Corporation 

333 Corporate Woods Parkway 
Vernon Hills, Illinois 60061-3109, USA 

have been shown to comply with the applicable technical standards of the FCC 

for Home, Office, Commercial and Industrial use 



if no unauthorized change is made in the equipment 
and if the equipment is properly maintained and operated. 




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Contents 



Welcome 

Getting Started 
Communications 
Printer Power 

Printer Configuration 

Z Series™ Configuration 

Media & Ribbon Loading 

Loading Media 
Loading Ribbon 
Removing Ribbon 

Media Sensor Positioning 

Media Sensor Operation 
Media Sensor Position 
Printer Operational Check 

Printer Operation 

Operator Interface 

Front Panel Keys 

Front Panel LEDs 

Additional Front Panel Controls 



5 

7 
8 

9 
9 

10 

13 
13 

14 
14 



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Media Calibration 

Auto-Calibration 17 

Calibration Control 17 

Care & Adjustments 

Cleaning 19 

Lubrication 24 

Printhead Pressure Adjustment 24 

Power Rewind/Power Peel 

Media Alignment 25 

Printer Options 

LCD Display (Deluxe Front Panel) 27 

Power Rewind/Power Peel Option 28 

Value Peel Option 30 

Cutter Option 3 1 

Electronics Options 33 

Communication Options 33 

Troubleshooting 

Power On Self-Test 35 

Troubleshooting Tables 35 

Printer Self-Tests 38 

Resetting Factory Defaults 44 

Initializing the Flash Memory and PCMCIA Card 45 

Automatically Executed Format 45 

Print Error Conditions 46 



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Printer Specifications 

General Specifications 47 

Printing Specifications 48 

Ribbon Specifications 48 

Media Specifications 49 

Zebra Programming Language (ZPL II®) 50 

Bar Codes 50 

Standard Printer Fonts 5 1 

Optional Printer Fonts 53 

Appendix A 

Printer Configuration (Standard Front Panel) 55 

Printer Configuration (Deluxe Front Panel) 59 

Appendix B 

Communication Interfaces 69 

Serial Data Communications 69 

Parallel Data Communications 72 

Appendix C 

AC Power Cord 73 

Fuse Replacement 74 

Shipping 74 

Setting Darkness For "In-Spec" Bar Codes 74 

ASCII Code Chart 77 

Glossary 
Index 



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Welcome 



Congratulations! You have just purchased a high-quality thermal de- 
mand printer manufactured by the industry leader in quality, service, 
and value. For over 25 years, Zebra Technologies Corporation has 
provided customers with the highest caliber of products and support. 

This user's guide provides all the information you will need to operate 
the printer on a daily basis. 

To create and print label formats, refer to the ZPL II Programming 
Guide (part # 46469L). This guide is available by contacting your 
distributor or Zebra Technologies Corporation. 

In addition, label preparation software is available. Contact your dis- 
tributor or Zebra Technologies Corporation for further information. 

The Z Series™ Maintenance Manual (part # 77450L) contains the in- 
formation you may need to properly maintain your printer. 

Getting Started 

Unpacking 

Save the carton and all packing materials in case shipping is required. 

Inspect the printer for possible shipping damage: 

■ Check all exterior surfaces for damage. 

■ Raise the Media Access Door and inspect the Media Compartment 
for damage. 

Reporting Damage 

If you discover shipping damage: 

■ Immediately notify the shipping company and file a damage report. 

■ Retain the carton and all packing material for inspection. 

■ Notify your local Zebra distributor of the damage. 

Zebra Technologies Corporation is not responsible for any damage 
incurred during shipment of the printer and will not cover the repair of 
this damage under its warranty policy. Any damage claim should be 
filed with the shipping company. 

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For shipping information, refer to Appendix C. 



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Communications 

Refer to Figure 1 . The Z Series™ printer comes standard with both an 
Electronics Industries Association (EIA) RS-232 serial data interface(a) 
and a bi-directional parallel interface(b) compliant with the IEEE 1284 
standard. The serial interface is also configured for both RS-422/ 
RS-485 single drop and RS-485 multi-drop communication modes. 

NOTE: You must supply the interface cable for your application. See 
Appendix B of this manual for specific cable requirements. 




Printer Power 

The Power Supply in the Z Series™ printer automatically detects the 
applied line voltage and works in the 90 to 265 VAC range. 

Refer to Figure 1 . The AC Power Cord must have a three-prong female 
connector on one end which plugs into the mating connector(c) at the 
rear of the printer. If a power cable was not included with your printer, 
refer to Appendix C at the back of this guide. 

WARNING!! For personnel and equipment safety, always use 
a three-prong plug with an earth ground connection to the 
AC Power Source. 

Refer to Figure 1 . Insure that the AC Power ON/OFF Switch(d) is in 
the OFF (O) position before connecting the AC Power cord to a nearby 
electrical outlet. 




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Figure 1. Printer Rear View 



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Printer Configuration 



Z Series™ Configuration 

The Z Series™ printer will have one of two different styled front pan- 
els. The deluxe front panel contains an LCD (Liquid Crystal Display), 
but the standard front panel does not. With the deluxe front panel, the 
LCD displays the parameters during the configuration process. For 
those printers with the standard front panel, two banks of eight minia- 
ture switches located inside the printer's front panel access door are 
used when configuring the printer. 

Communications Parameters 

The Z Series™ printer is equipped with both serial data and parallel 
data communication interfaces. This permits two sources to send label 
formats to the printer. 

The first source to send a "Start of Label Format" command controls 
the printer. The printer will send a "printer busy" command to the 
second source to inhibit data transmission. 

The serial interface is factory preset to match the typical PC environ- 
ment with RS232 communication: 

9600 Baud, 8 Data Bits, 
No Parity, Xon/Xoff Handshaking. 

If you need to change your printer's serial communications settings to 
match those of your host computer, refer to Appendix A. If you do not 
know the settings of your host computer, refer to the instruction manual 
provided with the computer or your software application. 

See Appendix B of this guide for specific data communication cable 
requirements. 

The printer automatically senses if a parallel communications cable is 
connected from your host computer. 



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Operating Modes 

When shipped from the factory, the printer is preset to the most com- 
monly used modes of operation: 

Tear-Off Mode, Thermal Transfer Printing, 
Die-Cut Media, Serial Port RS-232 Communications. 

Refer to Appendix A to configure the parameters for the following: 

■ Options, such as Power Rewind/Power Peel, Value Peel, 
or Cutter 

■ Operating Modes 

■ Print Darkness 

■ Label Tear-Off/Cut-Off Position 

■ Image Position on the label 



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Media & Ribbon Loading 



Loading Media 

To load media, refer to Figure 2. 

1 . Raise the media cover. 

2. Press the Printhead Open Lever(e). 

[The Printhead Assembly(f) automatically springs up.] 

3. Fold down the Media Supply Guide(g) and slide it out as far from 
the printer frame as possible. 

4. Slide the Media Guide(h) out as far from the printer frame as pos- 
sible. 

5. Determine the type of media required for your application and fol- 
low the roll media or fanfold media loading procedure. 

NOTE: If your printer has either the Power Rewind/Power Peel, Value 
Peel, or Cutter option installed, refer to the Options section for media 
loading instructions. 



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Figure 2. Loading Media 



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Roll Media Loading 

To load roll media, refer to Figure 3. 

1. Place the roll of media on the Media Supply Hanger(i) and push it 
on all the way. 

2. Fold the Media Supply Guide(g) up and slide it against the outer 
edge of the media roll. 

3. Feed the media under the Media Spindle(j), under the Ribbon Sen- 
sor(k), and out the front of the printer. 

4. Slide the Media Guide(h) in until it is against the outer edge of the 
media. 

5. Close the Printhead Assembly and the Media Cover, or continue to 
"Loading Ribbon". 




Figure 3. Roll Media Loading 

Fanfold Media Loading 

To load fanfold media, place the media behind the printer and refer to 
Figure 4. 

1. Pass the fanfold media over the Media Supply Hanger(i). 

2. Fold the Media Supply Guide(g) up and slide it against the outer 
edge of the media. 

3. Feed the media under the Media Spindle(j), under the Ribbon Sen- 
sor(k), and out the front of the printer. 

4. Slide the Media Guide(h) against the outer edge of the media. 

5. Close the Printhead Assembly and the Media Cover, or continue to 
"Loading Ribbon". 



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Figure 4. Fanfold Media Loading 



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Loading Ribbon 

NOTE: The Ribbon Supply Spindle in your printer may be a 
"Dual-Tension" variety. Most applications require the spindle to be in the 
"Normal" position. The "Low-Tension" position is recommended only when 
wide ribbons are used and normal tension hampers the ribbon movement. 



To place this spindle in the "Normal" position, firmly pull out on the 
Spindle End- Cap until it clicks into place as shown in Figure 5a. To place 
the spindle in the "Low-Tension" position, firmly push in on the Spindle 
End-Cap until it clicks into place. 



SPINDLE END-CAP 
EXTENDED- 




SPINDLE END-CAP 
RETRACTED - 




Normal Position 



Low Tension Position 



Figure 5a. Ribbon Supply Spindle Positioning 



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Loading the Ribbon 

CAUTION: Always use ribbon that is wider than the media. The 
smooth backing of the ribbon protects the printhead from wear. 
(For Direct Thermal printing, do not load ribbon in the printer.) 

To load ribbon, refer to Figures 5a and 5b. 



1 . Place the roll on the Ribbon Supply Spindle(l) and push it on all 
the way. 

2. Pull the end of the ribbon over the Ribbon Sensor(k), under the 
Printhead assembly(f), and up over the Ribbon Guide Plate(m). 

3. Wind the ribbon onto the Take-up Spindle(n) for several turns in a 
clockwise direction. 

4. As you close the Printhead Assembly, keep the ribbon snug and 
free of wrinkles, and in line with the guide mark near the left edge 
of the Ribbon Guide Plate. 




Figure 5b. Ribbon Loading 

Removing Ribbon 

To remove the ribbon, turn the Release Knob on the end of the Take-up 
Spindle(n) counterclockwise and slide the ribbon off the Spindle. 



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Media Sensor Positioning 



Media Sensor Operation 

When the printer is turned ON, a Power ON Self Test is performed 
which checks the status of the electronic system and controls within the 
printer. Additional operating parameters are determined by the type of 
media being used and the position of the Media Sensor located behind 
the Platen and under the media. 

Non-Continuous (Labels, Notched Tags) Media 

This type of media has some type of physical characteristic (notch, 
black mark, gap between die-cut labels, etc.) which indicates the start- 
of-label position. The Media Sensor must be properly positioned to 
sense these indicators. 

Continuous Media 

Continuous media typically does not contain start-of-label indicators. 
Label length must be specified by commands sent to the printer. 

If you are using ZPL II, include a Label Length ( A LL) command in 
each label format you send to the printer (refer to your ZPL II Program- 
ming Guide). If you are using other software to drive your printer, refer 
to the instructions provided with that software. 

Media Sensor Position 

1. To properly position the Media Sensor(o), refer to Figure 6. 

2. With the Printhead Assembly open, turn the AC Power ON 

3. Look through the side of the print mechanism and locate the 
Media Sensor Positioning Lever(p). 

4. (non-continuous media - labels, notched tags) Move the lever 
across the width of the media to position the sensor in line with the 
start-of-label indicator (notch, black mark, gap between die-cut 
labels, etc). The glow of the red LED through the media can help 
to accurately position the sensor. 

(continuous media - no notch or opening to sense) Position the 



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sensor anywhere under the media so that an "Out-of-Media" condi- 
tion will still be sensed. 

5. Insure the media and ribbon are properly positioned within the 
print mechanism, then close the Printhead Assembly. 

6. Close the printer's media cover, then turn the printer power OFF. 




Figure 6. Sensor Positioning 

Printer Operational Check 

1 . To insure proper setup and to check the initial printer configura- 
tion, press and hold the CANCEL key while turning the printer 
power ON. {Release the CANCEL key once the front panel indica- 
tors begin to turn OFF.) 

2. After an initial time period when the Power ON Self Test is per- 
formed, the printer will feed out media while calibrating the label 
length, then print a configuration label. 

3. Check the current configuration printed on the label and note any 
parameters which must be changed to insure the printer fits your 
application. For information on changing the configuration for 
your specific application, refer to Appendix A. 

A visual check of the label also provides an indication of the print qual- 
ity. Media width and media thickness vary from one application to the 



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next. To maintain proper print quality, refer to the Care & Adjustments 
section later in this guide. 

Figure 7 illustrates a properly loaded Z Series™ printer. For loading 
media and ribbon in printers with the Power Rewind/Power Peel, Value 
Peel or Cutter options, see the Options section later in this guide. 




Figure 7. Printer Ready for Operation 



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Printer Operation 



Operator Interface 

The Z Series™ family of printers features either a standard or deluxe 
front panel. The deluxe front panel features a Liquid Crystal Display 
(LCD) that provides both printer status information and configuration 
option menus. This section of the user's guide presents information 
which is common to both printer front panels. Refer to Figures 8 and 9 
to locate the keys and LEDs discussed in this section. 

Front Panel Keys 

Feed Key 

The FEED key forces the printer to feed one blank label. If you press 
the FEED key while the printer is idle or paused, a blank label is fed 
immediately. If you press the FEED key while the printer is printing, 
one blank label is fed after the completion of the current batch of 
labels. Once the blank label has been fed, pressing the FEED key again 
will feed a second label. 

Pause Key 

The PAUSE key stops and restarts the printing process. The first time 
you press the PAUSE key, any partially printed label is completed; then 
the printing process is stopped. If the printer is idle when you press the 
PAUSE key, no new print requests are accepted. Press the PAUSE key 
a second time to resume the printing process. 

Cancel Key 

The CANCEL key only functions when the printer is paused. When 
you press the CANCEL key, the label format that is currently printing 
is canceled. If no label format is printing, then the next one to be 
printed is canceled. If there are no label formats stored in the printer 
and waiting to be printed, the CANCEL key is ignored. 

If you press the CANCEL key for an extended period of time (more 
than 3 seconds) the printer performs a "cancel all formats" operation. 
The printer discards all of the label format data it has received, and 
returns to the idle state. 



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Front Panel LEDs 

LEDs on the front panel are a quick indication of the printer's status. 
The LEDs listed below are common to all Z Series™/>r/«ter,s . 

POWER LED 

The POWER LED is always ON when the printer is turned ON. 

DATA LED 

The DATA LED is normally OFF. When data is received, the LED acts 
as follows: 

■ SLOW BLINK - Printer is unable to accept more data 

from the host 

■ FAST BLINK - Printer is receiving data 

■ LED ON - No data being received - data processing 

or printing still occurring. 
The DATA LED will also blink once when the CANCEL key is 
pressed and a format is successfully canceled. 

ERROR LED 

The ERROR LED is normally OFF. When an error occurs that causes 
an interruption in the printing process, the LED acts as follows: 

■ SLOW BLINK- Ribbon In Warning, Under Temp 

Warning, or Over Temp Error 

■ FAST BLINK - Printhead Open 

■ LED ON - Media Out, Ribbon Out, or Cutter Errors 
With the Deluxe Front Panel, the type of error will also be visible on 
the Liquid Crystal Display. 

PAUSE LED 

The PAUSE LED is normally OFF. When the LED is ON it indicates 
the printer has stopped all printing operations. If the printer is printing 
when a PAUSE condition is requested, the LED turns ON at the end of 
the current label. 

In the Peel operating mode, the PAUSE LED will blink when the label 
is available for removal. No printing occurs when the printer is in the 
Peel mode of operation and the Peel option is not installed. 

Additional Front Panel Controls 

The front panel door conceals the configuration and setup keys and/or 
switches inside. Refer to the Printer Configuration section of this guide 
to configure the printer for your application. 



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Figure 8. Standard Front Panel 




Figure 9. Deluxe Front Panel 



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Media Calibration 



Auto-Calibration 

The auto-calibration of the Z Series™ printer occurs at power ON and 
each time the printer recovers from error conditions such as media er- 
rors, ribbon errors, and printhead open errors. In the process of clearing 
an error, open and close the printhead then take the printer out of 
PAUSE. The printer will begin the auto-calibration process if all errors 
have been cleared. 

The printer automatically determines the label length, and media and 
ribbon sensor settings. 

When non-continuous media is sensed, the calibration process is fol- 
lowed by the label length calculation. Once the label length is deter- 
mined, the media feeds to the rest position and stops. 

The results of this calibration are stored in the printer's memory and are 
retained even if printer power is removed. These parameters remain in 
effect until the next calibration is performed. 

Calibration Control 

The auto-calibration process will not take place if the ZPL command or 
the deluxe front panel setting for "Media Power Up" or "Head Close" 
is set to either "feed" or "no motion." In these cases, the printer as- 
sumes the media is correctly positioned and starts printing without cali- 
brating. 

As long as the printhead is closed, a calibration may be performed. 
Calibration may clear error conditions that prevent media movement. 
Ribbon and media error conditions are cleared by calibration, unless an 
out-of- ribbon or out-of-media condition exists. 

NOTE: If your printer has the standard front panel, the Calibration 
function is controlled by a ZPL II command sent from the host computer. 
No front panel calibration control is available. 



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Care & Adjustments 



Cleaning 

CAUTION: Use only the cleaning agents indicated. Zebra Technolo- 
gies Corporation will not be responsible for damage caused by any 
other cleaning materials used on the Z Series™ printer. 

Table 1 provides a recommended cleaning schedule. Cleaning Swabs 
saturated with 70% Isopropyl Alcohol are available from your Zebra 
distributor as a Preventive Maintenance Kit (part # 01429). 




AREA 


METHOD 


INTERVAL 


See Figure 10 for parts callouts. 




After every roll of media (or 
500 feet of fanfold media) 
when printing in the direct 
thermal mode. 

After every roll of ribbon 
when printing in the 
thermal transfer mode. 


Printhead (q) 


Alcohol 


Platen Roller (r) 


Alcohol 


Media Sensor (o) 


Air Blow 


Media Path (See Figure 3 or 4) 


Alcohol 


Ribbon Sensor (k) 


Air Blow 


Ribbon Path (See Figure 5) 


Alcohol 


Cutter 
Assembly 


Dust build-up 
Adhesive build-up 


Air Blow 

Citrus-Based 
Cleaner 
such as 
Goo-Gone® 


After every two to three 
rolls of media. 

After every roll of media or 
more often depending upon 
your application and the 
type of media being cut. 


Tear-Off/Peel-Off Bar 


Alcohol 


Once per month. 


Peel Blade 


Alcohol 


After every roll of media or 
more often depending upon 
your application and media. 


Label Available Sensor (z) 
(See Fig. 17) 


Air Blow 


Once per six months. 



Table 1. Recommended Cleaning Schedule 

Cleaning the Exterior 

The exterior of the Z Series™ printer may be cleaned with a lint-free 
cloth. Do not use harsh, abrasive cleaning agents or solvents. If neces- 
sary, a mild detergent or desktop cleaner may be used sparingly. 



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Cleaning the Interior 

Remove any accumulated dirt and lint from the interior of the printer 
using a soft bristle brush and/or vacuum cleaner. 

Cleaning the Printhead and Platen Roller 

Inconsistent print quality, such as voids in the bar code or graphics, 
may indicate a dirty printhead. For best results, perform the following 
cleaning procedure after every roll of ribbon. 

NOTE: The printer can remain ON while you are cleaning the 
printhead. In this way all label formats, images, and all temporary 
parameter settings stored in the printer's internal memory will be saved. 

To clean the printhead, refer to Figure 10 and follow these steps: 

1 . Open the Media Compartment Door. 

2. Open the Printhead Assembly by pressing the Printhead Open 
Lever(e). 

3. Remove the media and ribbon (if present). 

4. Raise the Printhead Assembly by hand and, using a cleaning swab 
soaked in alcohol, wipe along the printhead(q) print elements from 
end to end. (The print elements are located within the brown strip 
just behind the chrome strip on the printhead.) Allow a few sec- 
onds for the solvent to evaporate. 

5. Rotate the platen roller(r) and clean thoroughly with a cleaning 
swab soaked in alcohol. 

6. Brush/vacuum any accumulated paper lint and dust away from the 
media and ribbon paths. 

7. Reload media and ribbon, close the printhead assembly, close the 
Media Compartment Door, and continue printing. 

Cleaning the Sensors 

Refer to Figure 10. The Media Sensor(o) and Ribbon Sensor(k) should 
be cleaned on a regular basis to ensure proper operation of the printer. 
For printers with the Value Peel option or the Power Rewind/Power 
Peel option installed refer to Figure 17 and clean the Label Available 
Sensor(z). Brush or vacuum any accumulated paper lint and dust away 
from the sensors. 



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Figure 10. Printhead and Platen Roller Cleaning 



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Cleaning the Cutter Module 

(For printers equipped with the Cutter option.) 

The Cutter Module requires periodic cleaning to remove paper dust 
and gummed label residue. If labels are not being cut properly, or if the 
cutter jams with labels, this is an indication that the cutter probably 
needs cleaning. The cleaning frequency depends on your application 
and the type of media you use. 

When the stationary cutter blade and the v-shaped moveable cutter 
blade become gummed up with label adhesive and/or paper debris, 
clean them according to the procedure below. Steps 4 and 5 detail the 
method of removal of the Cutter Module from the printer. This portion 
of the procedure will only be required when there is an extremely 
heavy buildup of adhesive residue. 

Refer to Figure 1 1 during the following cleaning procedure. 

1 . Turn the AC power off and unplug the printer power cord. 

2. Open the Media Door and press the Printhead Open Lever to raise 
the Printhead Assembly. 

3. Remove the thumb screw and lift off the Finger Guard (and Catch 
Tray if used). 

4. Use a 3 mm Allen Wrench to remove the cutter mounting screw. 

5. Carefully lift the Cutter Module up and away from the printer. 

6. Remove all paper and label residue from the cutter blades and 
housing. 

WARNING!! The cutter blades are very sharp. Take great 
care in the following step to insure personal safety. 

7. Use cotton swabs soaked with a citrus-based cleaner (Goo Gone) 
to remove all adhesive residue from the cutter blades. (While 
cleaning, rotate the cutter motor to access the entire length of the 
moveable blade.) 

8. If adhesive has accumulated on the Platen and the Tear/Peel Bar, 
clean these areas in a similar manner. 

9. When the cleaning is completed, reinstall the Cutter Module, the 
Finger Guard and the Catch Tray, if used. 

10. Install media, then close and latch the Printhead Assembly. 

1 1 . Connect the printer to an AC power source, and turn the printer on. 

12. The printer should be ready to print and cut labels once again. 



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MANUAL- 
ROTATION 
CONTROL 

Figure 11. Cutter Cleaning 



NOTE: Disassembly of the Cutter module should only be performed by a 
Service Technician. 



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M 



Cleaning the Peel Blade 

(For printers equipped with the Value Peel or Power Peel option.) 

1 . Open the Media Door and press the Printhead Open Lever to raise 
the Printhead Assembly. 

2. Refer to Figure 12. Open the Peel Mechanism by gently lifting up 
on the Media Plate and pivoting it toward you. 

3. Refer to Figure 12. The primary area requiring cleaning is the 
backside of the Separator Bar. 

4. Remove the major portion of the accumulated adhesive by pressing 
the sticky side of a blank label against the adhesive and lifting it 
away. (Do this step repeatedly until most of the adhesive is gone.) 

5. Aggressively wipe the area with a cloth soaked in alchohol to 
remove any residual adhesive. 

6. Move the media backing material out of the way to allow inspec- 
tion of the Tear/Peel Bar. 

7. If any adhesive has accumulated, repeat the cleaning process on 
the Tear/Peel Bar. 

8. When the cleaning process is completed, align the media backing 
material and return the Media Plate to the operating position. 

9. Align the ribbon (if used) as you close and latch the Printhead 

Assembly. 

10. Close the Media Door and resume operation. 




Figure 12. Peel Blade Cleaning 



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Lubrication 

CAUTION! No lubricating agents of any kind should be used on this 
printer! Some commercially available lubricants, if used, will damage 
the finish and the mechanical parts inside the printer. 

Printhead Pressure Adjustment 

Printhead pressure is adjustable to insure maximum print quality. Refer 
to Figure 13 and rotate the Pressure Adjustment Dials(s & t) clockwise 
to increase the pressure or counterclockwise to decrease the pressure of 
the printhead against the ribbon and/or media. 

The amount of pressure required varies from one application to the next 
and is determined by the type and thickness of the media as well as the 
media width. 

If using narrow media, you may need to reduce the pressure applied by 
the right hand dial to minimize the pressure over the unused printhead 




Figure 13. Printhead Pressure Adjustment 



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Power Rewind/Power Peel 
Media Alignment 

(For printers equipped with the Power Rewind/Power Peel option.) 



An adjustment to the Media Alignment Spindle allows the user to in- 
sure that the media or backing material is properly winding onto the 
Take-up Spindle. 

Refer to Figure 14. Turn the adjustment dial(v) clockwise to align the 
media/backing material more to the left. 

Turn the dial counterclockwise to align the media/backing material to 
align more to the right. 




Figure 14. Power Rewind/Power Peel Media Alignment 



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Printer Options 



LCD Display (Deluxe Front Panel) 

The Z Series™ printers include the option of replacing the standard 
front panel with a deluxe front panel containing a Liquid Crystal 
Display (LCD). 

The LCD shows several types of information. 

■ When the printer completes its Power ON Self Test, the LCD 
displays an "idle" message. 

PRINTER READY 
1024K Vxx.x.x 



GO 



While a format is printing, a label counter is displayed. 

PRINTING 
1 OF 99999999 



The LCD also indicates memory conditions when they occur. 

CREATING BITMAP BUILDING FORMAT 

STORING GRAPHIC STORING FORMAT 

STORING BITMAP STORING FONT 

The LCD also displays an error message when an error occurs. 

HEAD OPEN PAPER OUT 

RIBBON OUT RIBBON IN 

BUFFER OVERFLOW CUTTER JAMMED 

HEAD COLD HEAD TOO HOT 
OUT OF MEMORY 



NOTE: When an error condition is corrected, the top line of that error 
display indicates "ERROR CLEARED. " Once all of the errors have been 
cleared, press the PAUSE key to resume printing. 

■ When configuring the printer's operating parameters, the 

configuration menu is displayed on the LCD. Refer to Appendix A 
for printer configuration parameters. 



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Power Rewind/Power Peel Option 

The Z Series™ printer supports a rewind option, with the capability of 
rewinding an entire roll of printed labels (Rewind mode) or backing 
material only (Peel mode). This option is available as both a factory 
installed feature and a field-installable kit. 

Label Movement in Rewind Mode 

In the Rewind mode, labels are printed and fed forward in a continuous 
sequence. As printing continues, the media is wound onto the Take-Up 
Spindle. 

Label Movement in Peel Mode 

In the Peel mode, when a label is completely printed, the printer feeds 
the label forward to the take-label position. The label hangs from the 
printer and is held in place by that portion of the label still attached to 
the backing material. When the operator removes the label, the printer 
moves the next label forward to "pre-peel" a portion of the label from 
the backing. The label then backfeeds to be printed. As printing contin- 
ues, the backing material is wound onto the Take-Up Spindle. 

Refer to Appendix A for information on configuring the printer for 
either the Power Rewind or Power Peel mode of operation. 




Figure 15. Media Loading (Power Rewind Option) 



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Media Loading 

Refer to Figure 15 (Power Rewind) or Figure 16 (Power Peel) while 
loading media. 

1. Place the roll of media on the Media Supply Hanger(i) and push it 
on all the way. 

2. Fold the Media Supply Guide(g) up and slide it against the outer 
edge of the media roll. 

3. Press the Printhead Open Lever(e) and raise the Printhead Assembly. 

4. Feed the media under the Media Spindle(j), under the Ribbon Sen- 
sor(k), and out the front of the printer. 

5. Slide the Media Guide(h) in until it is against the outer edge of the 
media. 

6. Pull about three feet of media through the front of the printer. 

7. (For Power Rewind) Pass the media down over the Media 
Plate(u), through the printer housing, and under the Media Align- 
ment Spindle(v). 

(For Power Peel) Lift the Media Plate(u) and rotate it forward. 
Remove the labels from the backing material, then pass the back- 
ing over the Peel Bar(w), down behind the Media Plate(u), through 
the printer housing, and under the Media Alignment Spindle(v). 
Return the Media Plate to its operating position. 




Figure 16. Media Loading (Power Peel Option) 



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8. Loosen the thumbscrew and slide the Rewind Media Guide(x) out 
to the end of the spindle and rotate it to its horizontal position. 

9. Place an empty media core on the Rewind Spindle(y), wrap the 
media around the core, and turn the spindle counterclockwise to 
wind up the excess material. 

10. Rotate the Rewind Media Guide to its vertical position, slide it in 
against the media, and tighten the thumbscrew that locks it into 
position. 

1 1 . Go to the "Loading Ribbon" procedure earlier in this guide; then 
continue through the "Configuration" and "Media Sensor Position- 
ing" processes. 

Media/Backing Removal 

1 . Loosen the thumbscrew and slide the Rewind Media Guide(x) out 
to the end of the spindle and rotate it to its horizontal position. 

2. Cut the media/backing material prior to where it winds onto the 
Take-up Spindle. 

3. Slide the roll of media/backing material from the Take-Up Spindle. 



Value Peel Option 

The Z Series™ printer also features a Value Peel option, supporting the 
Peel-off mode. This option is available as both a factory installed fea- 
ture and a field installable kit. 

Label Movement in Peel Mode 

This option does not capture the backing material on a spindle. Instead, 

the backing drops down from the front of the printer. 

In the Peel mode, when a label is completely printed, the printer feeds 
the label forward to the take-label position. The label hangs from the 
printer and is held in place by that portion of the label still attached to 
the backing material. When the operator removes the label, the printer 
moves the next label forward to "pre-peel" a portion of the label from 
the backing. The label then backfeeds to be printed. 

Refer to Appendix A for information on configuring the printer for the 
Value Peel mode of operation. 



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Media Loading 

Refer to Figure 17 while loading media. 

1. Place the roll of media on the Media Supply Hanger(i) and push it 
on all the way. 

2. Fold the Media Supply Guide(g) up and slide it against the outer 
edge of the media roll. 

3. Press the Printhead Open Lever(e) and raise the Printhead Assembly. 

4. Feed the media under the Media Spindle(j), under the Ribbon Sen- 
sor(k), and out the front of the printer. 

5. Slide the Media Guide(h) in against the outer edge of the media. 

6. Lift the Peel Assembly(u) and rotate it forward, away from the printer. 

7. Pull about 12 to 18 inches of backing only down over the edge of 
the Peel/Tear Bar(w) and close the printhead. 

8. Return the Peel Assembly to its operating position. Insure the Assem- 
bly is reseated on the tabs of the Peel/Tear Bar(w), go to the "Loading 
Ribbon" procedure earlier in this guide; then continue through the 
"Configuration" and "Media Sensor Positioning" processes. 




Figure 17. Media Loading (Value Peel-Off Option) 



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Cutter Option 

The Z Series™ printer also features a cutter option. This option is avail- 
able as both a factory installed feature and a field installable kit. A label 
catch tray is included which holds up to 10 labels up to 6" in length. 

Label Movement in Cutter Mode 

When the label is completely printed, the printer feeds the media into 
the cutter mechanism. The cutter blade is activated and the printer 
waits for the cutter mechanism to complete its cycle. After cutting, the 
printer backfeeds the media to the rest position or to the start of the 
next label if another label is in the print queue. If the cut cycle is not 
completed, the printer automatically stops the print cycle and turns the 
ERROR LED ON. This will normally identify a cutter jam. 

Refer to Appendix A for information on configuring the printer for the 
Cutter mode of operation. 

Media Loading 

Refer to Figure 1 8 while loading media. 

1. Place the roll of media on the Media Supply Hanger(i) and push it 
on all the way. 

2. Fold the Media Supply Guide(g) up and slide it against the outer 
edge of the media roll. 

3. Press the Printhead Open Lever(e) and raise the Printhead Assembly. 




Figure 18. Media Loading (Cutter Option) 



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4. Feed the media under the Media Spindle(j), under the Ribbon Sen- 
sor(k), through the Cutter Module, and out the front of the printer. 

5. Slide the Media Guide(h) in against the outer edge of the media. 

6. Go to the "Loading Ribbon" procedure earlier in this guide; then 
continue through the "Configuration" and "Media Sensor Position- 
ing" processes. 



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Electronics Options 

PCMCIA Option 

An optional PCMCIA Port is available for the Z Series™ printer. 
This option is available as both a factory installed feature and a field 
installable kit. 

Access to the PCMCIA port is from the rear of the printer. Optional 
PCMCIA Memory Cards will provide non-volatile storage for label 
formats, downloadable fonts, graphics files, etc. The content of the 
PCMCIA Memory Card is not lost when power is turned OFF. 




DRAM Memory Option 

A 2 Megabyte memory upgrade is available for the Z Series™ printer 
as both a factory installed feature and a field installable kit. This addi- 
tional memory area can be used to store a higher quantity of label 
formats or larger label formats. The content of the DRAM Memory is 
lost when power is turned OFF. 

This option consists of an electronic memory device which is inserted 
into a holder on the Main Logic Board inside the printer. 

Flash Memory Option 

Two non-volatile memory options (a 1 Megabyte and a 2 Megabyte) 
are available for the Z Series™ printer. This additional memory area 
can be used to store optional printer fonts, graphic formats, and com- 
plete label formats. 



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Once the option is installed in the printer, information to be stored in 
Flash Memory is downloaded to the printer from the host computer. 
A specific ZPLcommand is then sent to the printer which causes the 
information to be stored in the Flash Memory. The content of the Flash 
Memory is not lost when power is turned OFF. 

Communication Options 

Ethernet 

Ethernet Thinnet and lOBaseT connectivity are available through an 
external connection to the parallel port at the rear of the printer. 

IPX, LAT, NetBIOS/Net BEUI, TCP/IP protocols are supported with a 
data burst rate of 150 KB. HP Bitronics mode is supported to provide 
bi-directional high-speed. It is SNMP compatible and supports MIB I, 
MIB II and Parallel MIB as well as MPSCON: (NOVELL Netware) PC 
console configuration utility IPX. 



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Troubleshooting 



Power On Self-Test 

A Power On Self Test (POST) is performed each time the printer is 
turned ON. During this test, the front panel LEDs will turn ON and 
OFF to ensure proper operation. At the end of this self test, only the 
POWER LED will remain lit. 

Once the Power ON Self Test is complete, the media is advanced to the 
proper rest position as determined by the programmed media feed set- 
ting. Continuous media is assumed to be at the proper rest position. 



Troubleshooting Tables 

The following tables provide trouble symptoms, a diagnosis of specific 
causes and a recommended action which should result in proper printer 
operation. 



SYMPTOM 


DIAGNOSIS 


ACTION 


All LEDs never light. 


No AC Power applied to 


Ensure the AC Power 




the printer. 


cable is connected to 
a working voltage 
source. 


Faulty AC Power Fuse. 


Refer to Appendix C for 






Fuse replacement 






procedures. 


No voltage available 


Call a Service 




from the internal power 


Technician. 




supply. 




Printer locks up when 


Printer not configured 


Refer to the PAUSE and 


running the Power On 


properly. 


FEED Key Self Test and 


Self Test with some or 




reload factory defaults; 


all LEDs ON. 




then reconfigure the 
printer for the 
application. 


Internal printer failure. 


Call a Service 






Technician. 



Table 2. Power ON Troubleshooting 



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SYMPTOM 


DIAGNOSIS 


ACTION 


Printer stops, PAUSE 
LED ON and ERROR 
LED FLASHING Fast. 


Printhead is not fully 
closed. 


Close printhead 
completely. 


Malfunctioning 
Printhead Open Sensor. 


Call a Service 
Technician. 


Printer stops, PAUSE 
LED BLINKING. 


Printer in Peel mode 
and no Peel option 
installed. 


Change printer 
operating mode to 
fit application. 


Printer stops. PAUSE 
LED ON and ERROR 
LED FLASHING Slow. 


Printhead element is 
overheated. 


Printer resumes printing 
when the printhead 
element cools. 


Dots missing in printed 
area of label. 


Printhead element bad. 
Print quality problems. 


Replace the printhead. 


Loss of printing 
registration on labels. 


Possible Media Sensor 
problem. 


Adjust Sensor Position 
and Call a Service 
Technician if necessary. 


Printer set for non- 
continuous media, but 
continuous media 
loaded. 


Set printer for correct 
media. 


Improperly adjusted 
Media Guides. 


Reposition Media 
Guides. 


Excessive Vertical Drift 
in Top-of-Form 
registration. 


Incorrect media loaded 
or Media Sensor 
adjustments. 


Reload Media and check 
Media Sensor position. 


Light vertical lines 
running through all 
labels. 


Dirty printhead. 


Clean printhead. 


Defective printhead 
elements. 


Replace the printhead. 


Light printing or no 
printing on the left or 
right side of the label. 


Too little printhead 
pressure. 


Adjust printhead 
pressure. 


Short printed lines at 
45° to label edge on left 
or right side of label. 


Too much Printhead 
pressure. 


Adjust Printhead 
pressure. 


Fine gray lines on blank 
labels at angles. 


Wrinkled ribbon. 


See Wrinkled Ribbon in 
this Table. 


Long tracks of missing 
print on several labels. 


Wrinkled ribbon. 


See Wrinkled Ribbon in 
this Table. 


Print Element damaged. 


Replace the printhead. 



Continued on the following page. 
Table 3. Printer Troubleshooting 



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SYMPTOM 


DIAGNOSIS 


ACTION 


Wrinkled ribbon. 


Ribbon fed through 
printer incorrectly. 


Reinstall ribbon. 


Incorrect Darkness 


Set to the lowest value 




setting. 


needed for good print 
quality. 


Incorrect Printhead 


Readjust Printhead 




pressure. 


pressure. 


Media not feeding 


Readjust Media Guides. 




properly; it is walking 






from side to side. 




Continuing problems. 


Call a Service Technician. 


Misregistration and 


Media was pulled when 


Open and close the 


misprint of 1 to 3 labels. 


motor was not moving. 


printhead so it 
calibrates to find the 
label length. 


Incorrect Media Sensor 


Reposition Media 




Position. 


Sensor. 


Media or ribbon 


Reload Media and 




improperly loaded. 


Ribbon. 


Changes in parameter 


Parameters are set or 


Reload the Factory 


settings did not take 


saved incorrectly. 


Defaults, reconfigure 


effect. 




the printer, cycle the 
Power OFF and ON. 


Continuing problems. 


Call a Service Technician. 


ZPL was sent to printer. 


Communications 


Check and reset 


but not recognized. The 


parameters or DIP 


communication 


DATA LED remains 


Switches are set 


parameters if needed. 


OFF. 


incorrectly. 




Prefix and delimiter 


Set the characters in the 




characters set in printer 


printer to match ZPL 




configuration do not 


format. 




match the ones sent in 






the ZPL Label Formats. 


Check Configuration 
Label for correct 
characters. 

If problem continues, 
check the ZPL format 
for changed ~CC, 
"■ CT, and ~ CD 
instructions. 



Continued on the following page. 



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SYMPTOM 


DIAGNOSIS 


ACTION 


In Peel-Off Mode, 
skewed or stuck labels. 


Glue material from 
back of labels causing 
media movement 
problems. 


Perform maintenance 
and clean the printer. 


Media and backing not 
aligned in printer. 


Check media guide 
positions. 


Labels are not being cut. 


Cutter Mode not 
selected. 


Reconfigure the printer. 


The Cutter is not cutting 
labels cleanly. 


Cutter is dirty. 


Clean Cutter Blades. 


Cutter Blades are dull. 


Replace Cutter Module. 


Labels are jamming up in 
the Cutter or are being 
cut more than once. 


Cutter is dirty. 


Clean Cutter Blades. 


Label length too short. 


Increase label length. 


Printing stops. 


Out of media. 


Load media. 


PAUSE, and 
ERROR LEDs 




Out of ribbon 


Load ribbon 


Solid ON. 


For 

printers 

with the 

Cutter 

Option 

installed. 


Media jammed in 
the Cutter. 


Remove media, clean 
Cutter if necessary. 


Cutter Module is dirty. 


Clean Cutter Module. 


If error condition persists after attempting each 
of the above solutions, call a Service 
Technician. 



ay 



Printer Self-Tests 

The Z Series™ printer is designed to work with most Zebra media and 
ribbon combinations, right out of the box. However, in some applica- 
tions, changes to the printer's configuration and mechanical settings 
may be required. For these situations, printer self-test labels can be 
used to check print quality and insure proper operation. 

These self-tests produce sample printouts and provide specific informa- 
tion which helps determine the operating conditions for the printer. 
Each self-test is enabled by pressing a specific Front Panel key or com- 
bination of keys while turning the AC Power Switch ON. Keep the 
key(s) pressed until the first front panel LED turns OFF. Once the 
Power-On Self Test is completed, the selected self test begins automati- 
cally. 

NOTES: Prior to performing self-tests, disconnect all data interface 
cables from the printer. 

When canceling a self-test prior to its actual completion, always turn the 
printer power OFF and then back ON to restart the printer. 



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Make sure that your print width is set correctly for the media you are 
using before you run any self-tests, othei~wise the test may print out on the 
platen. If your media is not wide enough or long enough to display a 
complete test label, unexpected and/or undesired results may occur. 

When performing these self-tests while in the Peel Mode, you must 
remove the labels as they become available. 



CANCEL Key Self-test 

Press and hold the CANCEL key while turning the printer power ON. 
Release the key anytime after the first front panel LED turns OFF. 
The CANCEL key self-test prints a configuration label showing: 

■ Printer configuration ■ Installed options 

■ Software version ■ Copyright notice 

Figure 19 shows an example of the Printer Configuration Label. The 
configuration information will print over several labels if a label is not 
long enough to display all of the configuration information at one time. 



PRINTER 


CONFIGURATION 


+ 10 


DARKNESS 


+ 000 


TEAR OFF 


TEAR OFF 


PRINT MODE 


NON-CONTINUOUS 


MEDIA TYPE 


WEB 


SENSOR TYPE 


THERMAL-TRANS. 


PRINT METHOD 


184 0/3 MM 


PRINT WIDTH 


1228 


LABEL LENGTH 


RS232 


SERIAL COMM. 


NONE 


Z-NET PORT 


19200 


BAUD 


8 BITS 


DATA BITS 


NONE 


PARITY 


XON/XOFF 


HOST HANDSHAKE 


NONE 


PROTOCOL 


000 


NETWORK ID 


NORMAL MODE... 


COMMUNICATIONS 


< > 7EH 


CONTROL PREFIX 


<"> 5EH 


FORMAT PREFIX 


<,> 2CH 


DELIMITER CHAR 


ZPL II 


ZPL MODE 


CALIBRATION... 


MEDIA POWER UP 


CALIBRATION... 


HEAD CLOSE 


DEFAULT 


BACKFEED 


+000 


LABEL TOP 


+0000 


LEFT POSITION 


015 


WEB S. 


069 


MEDIA S. 


072 


RIBBON S. 


1S8 


MEDIA LED 


134 


RIBBON LED 


+ 10 


LCD ADJUST 


DPSWFXM 


MODES ENABLED 




MODES DISABLED 


832 8/MM FULL. 


RESOLUTION 


VXX.X.X <- 


FIRMWARE 


CUSTOMIZED 


CONFIGURATION 


1024k 


MEMORY 


NONE 


B: MEMORY 


INSTALLED 


E= MEMORY 


1-7 


CHIP ID 


NONE 


OPTION 



FIRMWARE IN THIS PRINTER IS COPYRIGHTED 

V J 

Figure 19. CANCEL Key Self-test Label 



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PAUSE Key Self-test 

Press and hold the PAUSE key while turning the printer power ON. 
Release the key anytime after the first front panel LED turns OFF. 
The PAUSE key self-test prints a series of labels which can be used 
when making print quality adjustments. 

■ 9999 labels at two inches per second pausing every 15 labels 

■ 9999 labels at six inches per second pausing every 1 5 labels 

■ 9999 labels at two inches per second pausing every 50 labels 

■ 9999 labels at six inches per second pausing every 50 labels 



When the printer pauses, press the PAUSE key to restart printing at the 
same speed. While paused, press the CANCEL key to switch to the 
next set of labels. 

Figure 20 provides an example of the PAUSE key self-test label. 





Figure 20. PAUSE Key Self-Test Label 



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FEED Key Self-test 

Press and hold the FEED key while turning the printer power ON. Re- 
lease the key anytime after the first front panel LED turns OFF. 

The quantity of labels printed during this print quality test depends on 
the dot density of the printhead. 

■ 300 dpi printers: 7 labels are printed at the 2 ips and 6 ips print 

speeds. 

■ 200 dpi printers: 7 labels are printed at the 2 ips, 6 ips and 10 ips 

print speeds. 
Each label is printed at a different darkness setting, starting at three set- 
tings below the currently configured value and continuing to increase 
until it is three settings darker than the configured value. The relative 
darkness and speed are printed on each label. The bar codes on these 
labels can be ANSI-graded to check print quality. 

Figure 2 1 provides an example of the FEED key self-test label. 



Relative Darkness:0 Print Speed: 2 irVsec 

VX.X.X 





















= ^^^= 






^^^^= s^^= 


^= s 1 ^^^^m 
















tf ^ 






















^^^^^^^^ ^^^^= 


^— W^^^ 


^^^m 3* tJ i 








^^^^^ 


^= ro 




= = 




^^^= X X 




: : ::: 



ABCDEFGHIJKLMNOPQRSTUvWXYZ 
abcdefghijklmnopqrstuvwxyz 




Figure 21. FEED Key Self-Test Label 



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PAUSE and CANCEL Key Self-test 

Press and hold both the PAUSE key and CANCEL key while turning 
the printer power ON. Release both keys anytime after the first front 
panel LED turns OFF. 

The PAUSE and CANCEL key self-test prints a sequentially numbered 
series of 500 labels. When making print quality adjustments, these la- 
bels should be observed o insure the highest print quality has been set. 

Figure 22 provides an example of the FEED key self-test label. 




Figure 22. PAUSE and CANCEL Key Self-test Label 



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CO 



Communications Diagnostic Self-test 

The Communications Diagnostic Mode is a troubleshooting tool for 
checking the interconnection between the printer and the host com- 
puter. When "Diagnostics" is selected, all data sent to the printer will be 
printed as straight ASCII hex characters. The printer prints all received 
characters including control codes like CR (Carriage Return). 

To enter the Communications Diagnostics mode, open the front panel 
door and press and hold the + key while turning the printer power ON. 
Release the key anytime after the first front panel LED turns OFF. 

Send a label format from the host computer to the printer and observe 
the printout on the label stock. Figure 23 provides an example of the 
Diagnostic Mode printout. 

NOTES: An FE indicates a framing error. 

An OE indicates an overrun error. 
An PE indicates a parity error. 
An NE indicates noise. 



If errors are indicated, check that your 
communication parameters are correct. 



^FS^F0394 , 25^AA 

5E 46 53 5E 46 4F 33 39 34 2C 32 35 5E 41 41 

N, 18, 10^FDC0000 

4E 2C 31 38 2C 31 30 5E 46 44 28 30 30 30 30 

)999-9999^FS 

29 39 39 39 2D 39 39 39 39 5E 46 53 0D 0A 

^FO0 , 50^AAN ,18, 

5E 46 4F 30 2C 35 30 5E 41 41 4E 2C 31 38 2C 

10^FDCENTER STA 

31 30 5E 46 44 43 45 4E 54 45 52 20 53 54 41 
Figure 23. Communications Diagnostics Self-test 



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® 



Media and Ribbon Sensor Profile 

The Media and Ribbon Sensor Profile may be used to troubleshoot reg- 
istration problems that may be caused when the Media Sensor experi- 
ences difficulty in determining web location between labels. 

To print a Media and Ribbon Sensor Profile, you must press and hold 
the PAUSE key, FEED key, and CANCEL key while turning the 
printer power ON. Release all three keys anytime after the first front 
panel LED turns OFF. Figure 24 provides an example of the Media and 
Ribbon Sensor Profile sample printout. 



MEDIA. 
WEB_ 




I I 






MEDIA MEDIA MEDIA MEDIA MEDIA 



Figure 24. Media & Ribbon Sensor Profile 

Resetting Factory Defaults 

From time to time, it may be necessary to return the printer configura- 
tion to a "known" state. A set of Factory Defaults can be loaded into 
the printer as a starting point from which one can then reconfigure the 
printer for the application desired. 

To reset Factory Defaults, press and hold both the PAUSE and FEED 
keys while turning the printer power ON. Release both keys anytime 
after the first front panel LED turns OFF. Once the Power-On Self Test 
is completed, open the printer's front panel door and press the Print 
Darkness Key two times to save the Factory Defaults parameters in 
EEPROM memory. To signify that the parameters have been saved, all 
three Control LEDs will flash on then off. 

(An alternate method of setting Factory Defaults is by sending the ZPL 
commands " A JUF A JUS" to the printer.) In addition, for printers with 
the deluxe front panel, factory default settings may be saved through 
the LCD configuration. 

As of Firmware Release V22.8.4, this process no longer initializes the 
optional on-board flash menory device nor the optional PCMCIA Card. 



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cCp 



Initializing the Flash Memory and 
PCMCIA Card 

As of Firmware release V22.8.4, a new procedure is used to initialize 
the optional on-board Flash Menory device and the optional PCMCIA 
Card. 

Prior to uploading new contents into the Flash Memory and/or the 
PCMCIA Card, it is first necessary to initialize these devices. This pro- 
cedure is performed by pressing and holding all three left hand control 
keys inside the printer's front panel door while turning the printer 
power ON. The keys may be released anytime after the first front panel 
LED turns OFF. The Front Panel DATA LED will remain on until the 
initialization process is finished. 

NOTE: Initialization will erase the current contents of both devices. 
Be sure to enable the Write Protect feature of the PCMCIA Card if you do 
not want to initialize this device. 



Automatically Executed Format 

Once the Power On Self Test is completed and any self test labels are 
printed, a check is made of the optional PCMCIA Memory Card and 
then the optional Flash Memory for the presence of a stored format 
named AUTOEXEC.ZPL. If an AUTOEXEC.ZPL format is encoun- 
tered, it is automatically recalled and the preformatted labels are 
printed. 

If no AUTOEXEC.ZPL format is found, the printer enters the normal 
operating mode and waits for operator input from the front panel or la- 
bel format data to be received from the host computer. 



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<£) 



Print Error Conditions 

There are several error conditions that effect printing. Some actually 
stop the printing process completely, while others are only reported to 
the operator or host system. A printhead open error condition stops any 
media movement, while the printhead under temperature error has no 
effect on media movement. Some error conditions must be corrected 
before the printer will feed or print labels again. 

Media Out, Ribbon Out, Head Open, or Cutter Error 

A media out, ribbon out, or cutter error condition stops the printer im- 
mediately and turns the ERROR LED on solid. A head open condition 
also stops the printer and the ERROR LED blinks. The label being 
printed, when the condition occurs, is only partially printed. The 
PAUSE LED is turned ON and the printer waits for the errors to be 
cleared and the PAUSE key to be pressed. If all error conditions are 
cleared when the PAUSE KEY is pressed, the PAUSE LED will turn 
OFF. Media registration occurs through the auto-calibration function 
(for non-continuous media) and then the printing process resumes. 

Printing resumes by reprinting the label that was in process when the 
condition occurred, unless the printer is configured to NOT reprint par- 
tial labels. All of the other features of the printer (e.g., communica- 
tions, parsing, formatting, and cancel) function normally during the 
error condition and while the printer is "recovering." 

The feature of reprinting a label after an error condition occurs can be 
turned off by a ZPL command. The type of media (continuous or non- 
continuous) being monitored by the printer is controlled by a setting on 
the front panel (LCD or DIP switches). 

Printhead Over Temperature 

When the printhead becomes too hot, all printing stops and the 
ERROR LED blinks slowly. The printer will wait until the printhead 
has returned to an acceptable temperature prior to restarting. All of the 
other features of the printer function normally while the head is over- 
temperature, including feeding and calibrating without printing a label. 

Printhead Under Temperature 

A similar condition occurs when the printhead is cooler than desired. 
The printer does NOT stop but the ERROR LED blinks slowly to indi- 
cate the error condition. All other printer features continue to work nor- 
mally. This includes printing, which should heat the printhead to the 
desired temperature. 



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Printer Specifications 



tCr 



NOTE: Printer specifications are subject to change without notice. Your 
printer may not have all of the options described in these specifications. If 
you have questions as to the ability of the Z Series™ printer to meet the 
needs of your application, contact either your Zebra Distributor or Zebra 
Technologies Corporation. 



General ! 


Specifications 




SPECIFICATION 


Z4000 PRINTER 


Z6000 PRINTER 


Height 


11.5" (292.5 mm) 


11.5" (292.5 mm) 


Width 


8.25" (209.6 mm) 


12.8" (325.1mm) 


Depth 


16" (406.4 mm) 


18.3" (464.8 mm) 


Weight (option-dependent) 


24.5 lbs. (11.1 kg) 


26.5 lbs. (12.0 kg) 


Electrical 


90 to 265VAC, 48-62 Hz 


5 Amps (Fused) 


Agency Approvals 


Built to CISPR 22B, IEC 950, 801-2,-3, and -4 

standards. 

Complies with FCC class "B" and Canadian Doc. 

class "A" rules. 

Carries the CE mark of compliance. 


Temperature 


Operating 


40°Fto 105°F(5°Cto40°C) 


Storage 


-40° F to 140° F (-40° C to 60° C) 


Relative Humidity 


5% to 85%, non-condensing 


Communications Interfaces 


RS-232/CCITTV.24and RS-485 Serial Data 
Interface; 1 10 to 38400 Baud, Parity, 
Bits/Char., and Xon-Xoff or DTR/DSR 
Handshake Protocols - all selectable. 


RS-485 Serial Data Interface; 110 to 38400 
Baud, Parity, Bits/Char. All selectable. 
Xon-Xoff Handshake Protocol required. 


8-Bit Parallel Data Interface; Supports IEEE 
1284 bi-directional parallel communications in 
"nibble mode" 






Error Detection CRC Protocol 



Table 4. General Specifications 

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Printing Specifications 






PRINTING SPECIFICATIONS 


Z4000 
PRINTER 


Z6000 
PRINTER 


Print Resolution 


203 dpi (8 dots/mm) 
or 300 dpi (11.8 dots/mm) 


Dot size 


203 dpi 
300 dpi 


0.00492" (0.125 mm) square 
0.0033" x 0.0039"(0.84 mm x 0.99 mm) 


Maximum print width 


4.1" (104 mm) 


6.6" (168 mm) 


Print length 


Minimum 


1 dot row 


Maximum 
continuous 
media 
(* 39" Max 
for non- 
continuous 
media) 


Std memory 

8 dot/mm 

12 dot/mm 


37" (940 mm) 
16" (406 mm) 


23" (584 mm) 
10" (254 mm) 


Opt memory 

8 dot/mm 

12 dot/mm 


*136"(3.5m) 
*61"(1549mm) 


*84"(2.1 m) 
38" (965 mm) 


Bar code modulus ("X") dimension 


5 mil to 50 mil 


Programmable constant printing speeds 


2"/sec. ( 50.8 mm/sec.) 


3"/sec. ( 76.2 mm/sec.) 


4"/sec. (101.6 mm/sec.) 


5"/sec. (127.0 mm/sec.) 


6"/sec. (152.4 mm/sec.) 


Additional printing speeds for printers with 
the 203 dots/inch (8 dots/mm) printheads. 


7"/sec. (177.8 mm/sec.) 


8"/sec. (203.2 mm/sec.) 


9"/sec. (228.6 mm/sec.) 


10"/sec. (254.0 mm/sec.) 


Thin film printhead with Energy Control 



Table 5. Printing Specifications 

Ribbon Specifications 



RIBBON SPECIFICATION 


Z4000 PRINTER 


Z6000 PRINTER 


Ribbon Width {Zebra 
recommends using ribbon 
at least as wide as the 
media to protect the 
printhead from wear. ) 


Minimum 


.94" (23.9 mm) 


1.57" (39.9 mm) 


Maximum 


4.3" (110 mm) 


6.85" (174 mm) 


Standard 
Lengths 


2:1 media to ribbon roll ratio 


984' (300 m) 


3:1 media to ribbon roll ratio 


1476' (450 m) 


Ribbon core inside diameter 


1.0" (25.4 mm) 



Table 6. Ribbon Specifications 



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Media Specifications 



MEDIA SPECIFICATION 


Z4000 
PRINTER 


Z6000 
PRINTER 


Total media 
width 


Maximum 


4.5" (115 mm) 


7.0"(178mm) 


Minimum 


1.0" (25.4 mm) 


2.0"(50.8 mm) 


Label length 


Maximum 


See "Printing Specifications" 


Minimum 


Tear-Off 
Mode 


0.5" (12.7 mm). 


Rewind 
Mode 


0.5" (12.7 mm) 


Peel-Off 
Mode 


1.0" (25.4 mm) 


Cutter 
Mode 


1.0" (25.4 mm) 


Total thickness 
(includes liner) 


Maximum (If above 0.01", 
printhead pressure may 
need adjustment) 


0.010" (0.25 mm) 


Minimum 


0.0023" (0.058 mm) 


Core size 


3.0" (76.2 mm) 


Maximum roll diameter 


8.0" (203 mm) 


Inter-label gap 


Maximum 


0.157" (4 mm) 


Minimum [0.118" (3 mm) 
preferred] 


0.079" (2 mm) 


Ticket/tag notch size (Width x Length) 


0.236" (6 mm) x 0.12" (3.0 mm) 



Pressure sensitive media: release liner must be free of preprint (with 
the exception of black mark registration) and is recommended to not 
exceed .0035" (.089 mm) thickness (60 lb stock). 

Table 7. Media Specifications 



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Zebra Programming Language (ZPL II®) 

■ Downloadable graphics (with 
data compression) 



Bit image data transfer and print- 
ing, mixed text/graphics 

Format inversion 

Mirror image printing 

Four-position field rotation 
(0°, 90°, 180°, 270°) 

Slew command 

Serialized fields 



Programmable quantity with print 
pause 

Communicates in printable 
ASCII characters 

Controlled via mainframe, mini, 
PC, Portable Data Terminal 

In-Spec OCR-A and OCR-B 

UPC/EAN [nominal 100% mag- 
nification (6 dot/mm printheads 
only)] 



Bar Codes 

■ Code 1 1 

■ Code 39 (supports ratios 
of 2:1 to 3:1) 

■ Code 49 (2-dimensional 
bar code) 

■ Code 93 

■ Code 128 (supports serial- 
ization in all subsets and 
UCC case codes) 

■ Codabar (supports ratios 
of 2:1 to 3:1) 

■ Codablock 

■ Interleaved 2 of 5 (supports 
ratios of 2:1 to 3:1, modulus 
10 check digit) 

■ Industrial 2 of 5 

■ Standard 2 of 5 



LOGMARS 

Plessey 

EAN-8, EAN-13, 
EAN EXTENSIONS 

UPC-A, UPC-E, 
UPC EXTENSIONS 

MSI 

PDF-417 (2-dimensional 
bar code) 

POSTNET 

MaxiCode 

Datamatrix 

QR Code (added with 
Firmware Release V22.8.3 

Check digit calculation 
where applicable 



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Standard Printer Fonts 

For more information on fonts, refer to the ZPL II Programming Guide. 



203 DOTS/INCH (8 DOTS/MM) PRINTHEAD 


Fonts 


Dot Matrix 
(hx w) 

(Defaults) 


Type* 


Minimum 

Character 

Size (h x w) 


Max 

Char 

/In 


A 


9x5 


U-L-D 


0.044" x 0.030" 


33.3 


B 


11x7 


U 


0.054" x 0.044" 


22.7 


C, D 


18x 10 


U-L-D 


0.089" x 0.059" 


16.9 


E 


28x 15 


OCR-B 


0.138" x 0.098" 


10.2 


F 


26x 13 


U-L-D 


0.128" x 0.079" 


12.7 


G 


60x40 


U-L-D 


0.295" x 0.236" 


4.2 


H 


21 x 13 


OCR-A 


0.103" x 0.093" 


10.8 


GS 


24x24 


SYMBOL 


0.1 18" x 0.1 18" 


8.5 





15x 12 


SCALEABLE (SMOOTH) FONT 


* Type: U - Upper Case, L - Lower Case, D - Descenders 




300 DOTS/INCH (11.8 DOTS/MM) PRINTHEAD 


Font 


Dot Matrix 
(hx w) 

(Defaults) 


Type* 


Minimum 

Character 

Size (h x w) 


Max 

Char 

/In 


A 


9x5 


U-L-D 


0.030" x 0.020" 


50.8 


B 


11x7 


U 


0.036" x 0.030" 


33.8 


C, D 


18x 10 


U-L-D 


0.059" x 0.040" 


25.4 


E 


42x20 


OCR-B 


0.138" x 0.085" 


23.4 


F 


26x 13 


U-L-D 


0.085" x 0.053" 


19.06 


G 


60x40 


U-L-D 


0.197"x0.158" 


6.36 


H 


34x22 


OCR-A 


0.1 11"x 0.098" 


10.02 


GS 


24x24 


SYMBOL 


0.079" x 0.079" 


12.7 





Variable 


SCALABLE (SMOOTH) FONT 


* Type: U - Upper Case, L - Lower Case, D - Descenders 



Bit-mapped fonts A, B, D, E, F, G, H, and GS are expandable up to 
10 times, height- and width-independent. However, fonts E and H 
(OCR-B and OCR-A) are not considered in-spec when expanded. 

The Scaleable Smooth Font (CG Triumvirate™ Bold Condensed) is 
expandable on a dot-by-dot basis, height- and width-independent, 
while maintaining smooth edges, to a maximum of 1500 x 1500 
dots. 

IBM Code Page 850 International characters available in fonts A, B, 
D, E, F, G and through software control. 



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Standard Printer Font Examples 



FONT A - RBCDuduz 12345 

FONT 8 - m-BCDUXYZ 12345 

FONT D - AFJyz 1E3 

FONT E - (OCR-EO ABCxyz 123 

FONT F - ABCDwxyz 12345 

FONT G - Az4 

FONT H - (OCR-A) UPPER CASE 
FONT - (Scalable) ABCDwxyz 12345 
FONT GS - ® © 



Default Printer Fonts - 300 dots/inch (12 dots/mm) 



FONT A — ABCD 


xyz 12145 










FONT B — 


ABCDWXYZ 12345 










FONT D 


— ABCDwxyz 12345 










FONT 


E — (OCR- 


•B) 


ABCD 


.vxyz 


12345 


FONT F ■ ABCDwxyz 


12345 






FONT G 







A 


z4 


FONT 


H -- (OCR-A) 


UPPER 


CASE 


ONLY 


FONT - 


- (Scalable) ABCDwxyz 12345 








FONT GS 


— ® © 











Default Printer Fonts - 203 dots/inch (8 dots/mm) 



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Optional Printer Fonts 

There are many optional character fonts that can be purchased for your 
Z Series™ printer, in addition to those which are standard in the unit. 
From time to time, additions may be made to the list of available fonts. 
Contact your sales representative for further information. 

Once installed, the optional fonts can be used in addition to the stan- 
dard fonts available in the printer. Refer to your ZPL II Programming 
Guide or, if using another software package to drive your printer, to the 
instructions accompanying that package. 



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Appendix A 



Printer Configuration (standard Front Panel) 



<xy 



NOTE: To configure a Z Series™ printer having the optional deluxe 
front panel, refer to the information found later in this section. 

Serial Communications Parameters 

Refer to Figure 25. When using serial communication, the Bank One 
(left) switches inside the front panel door must match the communica- 
tion parameters of the printer with those of your host computer. When 
shipped from the factory, all switches are in the ON position. This pre- 
sets the printer to match the typical PC environment - 9600 Baud, 
8 Data Bits, No Parity, and Xon/Xoff Handshaking. 




Figure 25. Standard Front Panel 



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-^J 




ON 

I 

OFF 



DIP Switch 
Positions 



Refer to Table 8 if the settings need to be changed to match those of 
your host computer. If you do not know the settings of your host com- 
puter, refer to the instruction manual provided with the computer. 

The serial port supports an Error Detection Protocol which sends and 
receives data in packets. This "Zebra" protocol must be compatible 
with your host computer and your application software. Received 
packets are checked for accuracy. If received correctly, the data in the 
packet is processed and an "acknowledge" packet is sent back to the 
host. If an error is found in the received packet, either a "negative 
acknowledge" packet or no response will be sent to the host. DO NOT 
enable Error Detection unless your host is programmed to use it. For 
additional information, refer to the ZPL II Programming Guide. 

If the Bank One switches are in the proper position to match the com- 
munication configuration of the host computer, and the printer is not 
receiving data, see Appendix B to make sure you are using the correct 
interface cable. 



BAUD RATE 


SWITCH 1 


SWITCH 2 


SWITCH 3 


9600 


ON 


ON 


ON 


19200 


OFF 


ON 


ON 


28800 


ON 


OFF 


ON 


38400 


OFF 


OFF 


ON 


600 


ON 


ON 


OFF 


1200 


OFF 


ON 


OFF 


2400 


ON 


OFF 


OFF 


4800 


OFF 


OFF 


OFF 


DATA BITS 


SWITCH 4 


NOTE: The printer requires one (1) 
stop bit minimum on received data 
and automatically supplies two (2) 
stop bits for transmitted data. 


8 Data Bits 


ON 


7 Data Bits 


OFF 


HANDSHAKE 


SWITCH 5 




Xon/Xoff 


ON 


DTR/DSR 


OFF 


PARITY 


SWITCH 6 


SWITCH 7 




Parity Disabled 


ON 


ON 


Even 


OFF 


ON 


Odd 


ON 


OFF 


Parity Disabled 


OFF 


OFF 


ERROR DETECTION 


SWITCH 8 


NOTE: Zebra Protocol is the default 
Error Detection Protocol enabled 


Off 


ON 


On 


OFF 


when "On - Switch 


3 OFF" is selected. 



Table 8. Bank 1 Switch Settings 



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-e^i 




ON 



I 

OFF 



DIP Switch 
Positions 



Operating Modes 

Use the Bank Two (right) switches to select printer operating modes. 
When shipped from the factory, all switches are in the ON position. 
This presets the printer to match the most commonly used modes of 
operation - Tear-Off Mode, Non-continuous Media, Thermal Transfer 
Operation, and RS-232 Serial Communications. 

If your printer is equipped with an option such as rewind, peel-off, or 
cutter, or if your application requires a different operating mode such as 
direct thermal, or continuous media, refer to Table 9 for the appropriate 
Bank Two switch settings. 



DIP SWITCH/ZPL CONTROL 


SWITCH 1 




Dip Switches 2 - 6 Override ZPL 


ON 


ZPL Overrides Dip Switches 2 - 6 


OFF 


PRINT MODE 


SWITCH 2 


SWITCH 3 




Tear-Off 


ON 


ON 


Peel-Off 


OFF 


ON 


Cutter 


ON 


OFF 


Rewind 


OFF 


OFF 


MEDIA TYPE 


SWITCH 4 


SWITCH 5 




Non-Continuous 
Web Sensing 


ON 


ON 


Non-Continuous 
Mark Sensing 


ON 


OFF 


Continuous 


OFF 


OFF 


PRINT METHOD 


SWITCH 6 




Thermal Transfer 


ON 


Direct Thermal 


OFF 


SERIAL COM MODE 


SWITCH 7 


SWITCH 8 




RS-232 


ON 


ON 


RS-422/RS485 
Single-Drop 


OFF 


ON 


RS-485 Multi-Drop 


OFF 


OFF 



cO 



Table 9. Bank 2 Switch Settings 

NOTE: The printer automatically senses if a parallel communications 
cable is connected from your host computer. The Bank One switches and 
Bank Two switches 7 and 8 have no effect on parallel communications. 

To see a printout of the printer configuration, perform the CANCEL 
Key Self Test. See the "Troubleshooting" section for more details. 



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Standard Front Panel Control Keys 

If you need to adjust the print darkness, label position or the image po- 
sition on the label, use the following control keys located inside the 
front panel door to configure these parameters. 

Print Darkness Key 

Press this key (LED turns ON) to change the print darkness setting by 
pressing the PLUS (+) or MINUS (-) keys. Each press of the + or - key 
changes the setting by one step. Press the Print Darkness key a second 
time to save the new setting. The darkness setting limits are from zero 
(0) to 30. 

Label Position Key 

Press this key (LED turns ON) to change the label tear off/cut off 
position setting by pressing the (+) or (-) keys. Each press of the + or - 
key changes the setting by four dot rows. Press the Label Position key 
a second time to save the new setting. From the default value, the set- 
ting may be changed +120 or -120 dot rows. 

Image Position Key 

Press this key (LED turns ON) to change the image position setting by 
pressing the (+) or (-) keys. Each press of the + or - key changes the 
setting by four dot rows. Press the Image Position key a second time to 
save the new setting. From the default value, the setting may be 
changed +120 or -120 dot rows. 

Plus Key ( + ) 

When setting print darkness, each press of this key increases the dark- 
ness setting by 1 . 

When setting the label position, each press of this key moves the label 
tear off/cut off position four dot rows away from the end of the label 
just printed. 

When setting the image position, each press of this key moves the image 
four dot rows away from the leading edge of the label being printed. 

Minus Key ( - ) 

Pressing this key has the opposite effect on the settings from the PLUS 
key. 



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Printer Configuration (Deluxe Front Panel) 

NOTE: To configure a Z Series™ printer having the standard front 
panel, refer to the information found earlier in this section. 

Deluxe Front Panel Control Keys 

Refer to Figure 26. Opening the door on the front panel provides access 
to the control keys used for configuring the printer's operating features. 
The Liquid Crystal Display (LCD) shows the menus as you proceed 
through the configuration process. 




Figure 26. Deluxe Front Panel 

The configuration sequence is a series of menus and prompts with pro- 
grammable parameters for each menu listing. 

START/SAVE Key 

Press this key to enter the configuration mode. Once in the configura- 
tion mode, the first major menu selection (General Setup) is displayed. 



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NEXT MENU Key 

Press this key to increment through the major menu headings, showing 
the top level of each configuration section. When the end of the menu 
listing is reached, the list repeats automatically. 



NEXT ITEM Key 

Once the appropriate major menu is visible on the LCD display, the 
NEXT ITEM key can be used to sequence through the configuration 
prompts for that menu. When the end of the item listing is reached, the 
list repeats automatically. 

When the appropriate item is displayed, the PLUS (+) and MINUS (-) 
keys can be used to select the setting for that item. 



PLUS Key ( + ) 

Press this key to increment the value of the item selected on the LCD. 

MINUS Key ( - ) 

Press this key to decrement the value of the item selected on the LCD. 

NOTE: When entering specific numeric values, use the MINUS key to 
select the digit position and the PLUS key to select the value for that 
position. 



Front Panel Programming 

Table 10 provides the printer configuration parameters in the sequence 
in which they appear on the front panel LCD display. The DEFAULT 
value as well as the available choices for each parameter are given. 

Once in the configuration mode, pressing the NEXT MENU key at any 
time will exit the current major menu feature list and move to the next 
major menu heading. An asterisk "*" appears in the upper left corner of 
the LCD if the value selected is different from the one currently saved. 

NOTE: Whenever a password is requested during the configuration 
process, the default value of "1234" may be entered . This password may 
be changed via a programming command sent to the printer from the host 
computer. 



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GENERAL SETUP MENU 


PARAMETER 


SELECTIONS 


LANGUAGE 


Use the PLUS key or MINUS key to sequence 
through the LCD selections until the appropriate 
language is displayed. 

Default: English 

Choices: English, Spanish, French, German, Italian, 
Norwegian, Portuguese, Swedish, Danish, 
Spanish2, Dutch, Finnish or Custom. 


DARKNESS 


Set the darkness to the lowest setting possible for 
consistent high quality printing. 

To observe the effects of the newly entered value, 
go to the Print Listings parameter and print a setup 
label. 

Default: 10 Range: 0to30 


TEAR OFF 


This value sets the media rest position over the 
Tear/Peel Bar after printing or the cut-off point for 
cutter applications. 

Default: 00 Range: -120 to +120 


PRINT MODE 


Select a print mode that your hardware 
configuration supports, since some selections 
are for optional printer features. 

Default: Tear Off Choices: Tear Off, Rewind, 
Cutter, Peel Off 


LABEL TOP 


This value sets the print position vertically on the 
label. A more positive value moves the label top 
position farther down the label. A negative value 
moves the label top position up the label. 

Default: 00 Range: -120 to +120 


LCD ADJUST 


If the LCD is difficult to read, use the PLUS key or 
MINUS key to adjust the brightness of your display. 

Default: 10 Range: 00 to 19 



Continued on the following page. 



Table 10. Deluxe Front Panel Configuration 



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COMMUNICATIONS 


PARAMETER 


SELECTIONS 


BAUD 

(password 

required) 


Select the value that matches the one used by the 
host. 

Default: 9600 

Choices: 600, 1200, 2400, 4800, 9600, 
19200, 28800, or 38400 


DATA BITS 

(password 

required) 


Select the value that matches the one used by the 
host. (Must be set to 8 data bits to use Code Page 850.) 

Default: 8 bits/character 

Choices: 7 bits/character or 8 bits/character 

NOTE: The printer requires one (1) stop bit 
minimum on received data and 
automatically supplies two (2) stop bits 
for transmitted data. 


PARITY 

(password 

required) 


Select the value that matches the one used by the 
host. 

Default: None Choices: Even, Odd, None 


HOST HANDSHAKE 

(password 

required) 


Select the value that matches the one used by the 
host. 

Default: XON/XOFF 

Choices: XON/XOFF or DTR/DSR 


PROTOCOL 

(password 

required) 


Details on protocol can be found in the ZPL II 
Programming Guide, available from Zebra 
Technologies Corporation. 

Default: None Choices: None, Ack-Nak, Zebra 

NOTE: Zebra Protocol is the same as ACK/NAK 
except that with Zebra the response 
messages are sequenced. If Ack-Nak or 
Zebra is selected, then "DTR/DSR" Host 
Handshake must be selected. 


SERIAL COMM 

(password 

required) 


Select the choice that matches the one used by the 
host. 

Default: RS232 Choices: RS232, RS422/RS485, 
or RS485 Multidrop 



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COMMUNICATIONS 


PARAMETER 


SELECTIONS 


NETWORK ID 

(password 

required) 


The network ID is used to assign a unique number to 
a printer used in a network. This gives the host the 
means to address a specific printer. 

Default: 000 Choices: 000 to 999 

NOTE: If the printer is used in a network, you must 
select a network ID number 


COMMUNICATIONS 

(password 

required) 


The communications diagnostics mode is a trouble- 
shooting tool for checking the interconnection 
between the printer and the host. When "Diagnostics" 
is selected, all data sent from the host to the printer 
will be printed as straight ASCII hex characters. All 
received characters, including control codes like CR 
(Carriage Return), are printed. 

Default: Normal Mode 

Choices: Normal Mode or Diagnostics Mode 

NOTES: An FE indicates a framing error. 
An OE indicates an overrun error. 
An PE indicates a parity error. 
An NE indicates noise. 

If errors are indicated, check that your 
communication parameters are correct. 



PRINT LISTINGS 


PARAMETER 


SELECTIONS 


LIST FONTS 


Press "+" to print a list of all standard and optional 
fonts currently available in the printer. 


LIST BARCODES 


Press "+" to print a list of all the barcodes currently 
available in the printer. 


LIST IMAGES 


Press "+" to print a list of all the images currently 
available in the printer. 


LIST FORMATS 


Press "+" to print a list of all the formats currently 
available in the printer. 


LIST SETUP 


Press "+" to print the printer's current configuration. 


LIST ALL 


Press "+" to print all of the previously indicated lists. 



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MEDIA SETUP 


PARAMETER 


SELECTIONS 


MEDIA TYPE 


Select the type of media you are using. 

Default: Non-Continuous 

Choices: Continuous or non-continuous 

NOTE: Selecting continuous media requires that 
you include a label length instruction in 
your label format (~ LLxxxx - if you are 
usingZPLorZPLII). 


SENSOR TYPE 


Select the type of media sensing you will use: 

- Web if a gap, space, notch, or hole is used to 
indicate the separations between labels. 

- Mark if a black mark printed on the back of the 
media is used to indicate the separations between 
labels. (If your media does not have black marks 
on the back, leave the printer at the default - Web.) 

Default: Web Choices: Web or Mark 


PRINT METHOD 


Select the method of printing you wish to use. 

- Direct thermal requires the use of heat sensitive 
label stock (no ribbon needed). 

- Thermal transfer uses many types of label stock 
along with an inked ribbon. 

Default: Thermal transfer 

Choices: Thermal Transfer or Direct Thermal 

NOTE: Selecting direct thermal when using thermal 
transfer media and ribbon creates a warning 
condition, but printing will continue. 


PRINT WIDTH 


Select a print width that is the closest to and at least 
as wide as your media. Setting the width too 
narrow may result in unprinted portions of your 
label format. Setting the width too wide wastes 
formatting memory and may cause printing off the 
right side of the label. 

Default: 104 mm (Z4000) 
168mm(Z6000) 

Choices: Up to 104 mm (Z4000) 
Up to 168 mm (Z6000) 

NOTE: Move the curser under "mm" using the 

MINUS key, use the PLUS key to change the 
reading from mm to inches or dots. 



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CALIBRATION 


PARAMETER 


SELECTIONS 


MEDIA POWER UP 

(password 

required) 


This parameter establishes the action of the media 
when the printer is turned ON. 

Default: Calibration 

Choices: Calibration - recalibrates media and ribbon 
sensors by feeding labels 
Feed - feeds the label to the first web 
Length - determines the length of the label 

by feeding labels 
No Motion - media does not move 


HEAD CLOSE 

(password 

required) 


This parameter establishes the action of the media 
after the printhead has been opened and then 
closed. 

Default: Calibration 

Choices: Calibration - recalibrates media and ribbon 
sensors by feeding labels 
Feed - feeds the label to the first web 
Length - determines the length of the label 

by feeding labels 
No Motion - media does not move 


MANUAL CALIBRATE 


If the auto-calibration feature has been disabled by a 
ZPL command from the host or the HEAD CLOSE 
parameter is not "Calibrate", you may use this 
feature to calibrate the media and ribbon sensors. 

Press "+" to enable the Calibration process. 

NOTE: If the printer is configured for continuous 

media, no media movement will occur during 
the Calibration process. 


SENSOR PROFILE 


The Media and Ribbon Sensor Profile provides a 
graphical representation of the Media and Ribbon 
Sensor settings as an aid to the Service Technician if 
problems with inter-label gap sensing occur. 

Press "+" to enable the Sensor Profile printout. 


WEBS. 


THESE SETTINGS SHOULD ONLY BE CHANGED 

BY AN AUTHORIZED SERVICE TECHNICIAN. 

(A password is required) 

Refer to the Z Series Maintenance Manual for 
additional information about these settings. 


MEDIA S. 


RIBBONS. 


MEDIA LED 


RIBBON LED 



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ZPL CONTROL 


PARAMETER 


SELECTIONS 


CONTROL PREFIX 

(password 

required) 


The printer looks for this 2-digit hex value to 
indicate the start of a ZPL/ZPL II Control instruction. 
Refer to the ZPL II Programming Guide for more 
information. 

Default: 7E (tilde - displayed as a black square) 

Choices: most hex values between 00 and FF 

(exclude the values indicated on the ASCII 
Code Chart in Appendix C) 


FORMAT PREFIX 

(password 

required) 


The printer looks for this 2-digit hex value to 
indicate the start of a ZPL/ZPL II Format instruction. 
Refer to the ZPL II Programming Guide for more 
information. 

Default: 5E (caret) 

Choices: most hex values between 00 and FF 

(exclude the values indicated on the ASCII 
Code Chart in Appendix C) 


DELIMITER CHAR 

(password 

required) 


The printer looks for this 2-digit hex value used as a 
parameter place marker in ZPL/ZPL II instruction. 
Refer to the ZPL II Programming Guide for more 
information. 

Default: 2C (comma) 

Choices: most hex values between 00 and FF 

(exclude the values indicated on the ASCII 
Code Chart in Appendix C) 


ZPLMODE 
(password 
required) 


The printer will remain in the selected mode until it 
is changed by this parameter or by sending a 
ZPL/ZPL II command. The printer accepts label 
formats written in either ZPL or ZPL II. This 
eliminates the need to rewrite any ZPL formats you 
already have. Refer to the ZPL II Programming 
Guide for more information. 

Default: ZPL II 

Choices: ZPL II or ZPL 



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ADVANCED SETUP 


PARAMETER 


SELECTIONS 


BACKFEED 

(password 

required) 


In the Cutter mode, this parameter establishes 
when and how much label backfeed occurs after a 
label is cut. It has no effect in the Tear-Off, Peel, or 
Rewind modes. This parameter can be superseded 
by the — JS instruction when received as part of a 
label format. (Refer to the ZPL Programming 
Guide.) 

Default: Default (default is defined as 90%) 

Choices: Default, After, Off, Before, 10%, 20%, 
30%, 40%, 50%, 60%, 70%, 80% 

NOTE: The difference between the value entered and 
100% establishes how much backfeed occurs 
before the next label is printed. For example, a 
value of 40 means that 40% of the backfeed 
takes place after the label is cut. The remaining 
60% takes place before the next label prints. A 
value of "before" means that all backfeed will 
take place before the next label is printed. 


LEFT POSITION 


This parameter establishes how far from the left 
edge of a label the format will begin to print by 
adjusting the horizontal positioning on the label. 
Positive numbers adjust the printing to the left by 
the number of dots selected. Negative numbers 
shift printing to the right. 

Default: 000 

Choices: -9999 to +9999 

NOTE: For a negative value, enter the value before 
entering the minus sign. 


INITIALIZE CARD 

(password 

required) 


This parameter allows you to initialize (erase) the 
PCMCIA Card installed in the optional PCMCIA Port. 

Press + to initialize. Then, if not sure, press - for 
NO, or if you are sure, press + for YES. 


INIT FLASH MEM 

(password 

required) 


This parameter allows you to initialize (erase) the 
optional non-volatile memory installed in the 
printer. 

Press + to initialize. Then, if not sure, press - for 
NO, or if you are sure, press + for YES. 



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Exiting the Configuration mode 

When you are finished changing or reviewing the necessary parame- 
ters, press the START/SAVE key. Use the NEXT ITEM key to select 
one of the "SAVE" choices shown below; then press the START/ 
SAVE key again to end the configuration process. 

■ PERMANENT - new settings overwrite previous values in 

configuration memory. 

■ TEMPORARY - printer operates with new settings until power 

is turned off; when power is turned back on, the printer 
reverts back to the PERMANENT values. 

■ CANCEL - printer makes no changes and returns to the current 

settings. 

■ LOAD DEFAULTS - all values return to the factory settings. 

■ LOAD LAST SAVE - printer operates with last set of values 

saved (either permanent or temporary). 



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Appendix B 



Communication Interfaces 

Data cables must be fully shielded and fitted with metal or metalized 
connector shells to prevent radiation and reception of electrical noise. 
To minimize electrical noise pickup in the cable: 

■ Keep data cables as short as possible. 

■ Do not bundle the data cables tightly with power cords. 

■ Do not tie the data cables to power line conduits. 

Serial Data Communications 

Table 1 1 illustrates the pin connections on the DB-25 connector at the 
rear of the printer. 



PIN NO. 




1 


Chassis Ground 


2 


TXD (Transmit Data) output from the printer 


3 


RXD (Receive Data) input to the printer 


4 


RTS (Request To Send) output from the printer 


5 


Not Used 


6 


DSR (Data Set Ready) input to the printer 


7 


RS-232 Signal Ground 


8 


Not Used 


9 


+5V@ 1A source 


10 


Not Used 


11 


RS-485 Signal Ground 


12 


Not Used 


13 


RS-485 Input B (-) 


14 


RS-485 Output B (-) 


15 


Not Used 


16 


RS-485 lnputA( + ) 


17-18 


Not Used 


19 


RS-485 Output A ( + ) 


20 


DTR (Data Terminal Ready) output from the printer 


21-25 


Not Used 



Table 11. Rear Panel Serial Data Port Pinout 



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RS-232 Interface 

The Z Series™ printer is configured as Data Terminal Equipment 
(DTE). The serial data cable used to connect the printer to the host 
computer will be one of two styles: 

■ 9-pin to 25-pin cable - (NULL Modem Cable) must have a 9-pin 
"D" Type (DB9S) connector on the end that is plugged into the 
serial port at the computer and a 25-pin "D" Type (DB25P) 
connector on the other end that is plugged into the connector at the 
rear of the printer. Figure 27 shows the required cable connections. 



DB-25P 
Connector 
to Printer 




Figure 27. 9-Pin to 25-Pin Cable 



25-pin to 25-pin cable - (NULL Modem Cable) must have a 25-pin 
"D" Type (DB25S) connector on the end that is plugged into the 
serial port at the computer and a 25-pin "D" Type (DB25P) 
connector on the other end that is plugged into the connector at the 
rear of the printer. Figure 28 shows the required cable connections. 




Figure 28. 25-Pin to 25-Pin Cable 



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Hardware Control Signal Descriptions 

For all RS-232 input and output signals, the Z Series™ printer follows 
both the Electronics Industries Association (EIA) RS-232 and the Con- 
sultative Committee for International Telegraph and Telephone 
(CCITT) V.24 standard signal level specifications. 

When DTR/DSR handshaking is selected, the Data Terminal Ready 
(DTR) control signal output from the printer controls when the host 
computer may send data. DTR ACTIVE (positive voltage), permits the 
host to send data. When the printer places DTR in the INACTIVE 
(negative voltage) state, the host must not send data. 

NOTE: When Xon/Xoff handshaking is selected, dataflow is controlled 
by the ASCII Control Codes DC1 (XON) and DC3 (XOFF). The DTR 
Control lead will have no effect. 

Request To Send (RTS) is a control signal from the printer which is 
connected to the Clear To Send (CTS) input at the host computer. RTS 
is always ACTIVE (positive voltage) when the printer is ON. 

CAUTION: The Z Series™ printers comply with FCC "Rules and 
Regulations", Part 15 for Class B Equipment, using fully shielded 
six-foot data cables. Use of longer cables or unshielded cables may 
increase radiated emissions above the Class B limits. 

RS-485 Interface 

Figure 29 illustrates the pin connections on the DB-25 connector at the 
rear of the printer which are used for the RS-485 communication 
protocol. 

NOTE: Xon/Xoff handshaking must be used for RS-485 communications. 



DB-25P 
Connector 
to Printer 



^1 



Shield 



Signal Ground Reference 



Data Input A (-) 



Data Output A (- 



Data Input B (+) 



J* 



Data Output B (+) 



1 
11 

13 
14 

16 

19 



Figure 29. RS-485 Cable 



Z Series™ User's Guide 



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Parallel Data Communications 

Table 12 illustrates the pin connections on the Bi-directional Parallel 
connector at the rear of the printer. 

Parallel Interface 

The 8-Bit Parallel Data Interface supports IEEE 1284 bi-directional 
parallel communications in "nibble mode". The parallel interface pro- 
vides a means of communication which is typically faster than the pre- 
viously mentioned serial interface methods. In this method, the bits of 
data which make up a character are sent all at one time over several 
wires in the cable, one bit per wire. 

Parallel Cabling Requirements 

An IEEE 1284 compatable bi-directional parallel data cable is required 
when this communication method is used. The required cable must 
have a standard 36-pin parallel connector on one end which is plugged 
into the mating connector located at the rear of the printer. The other 
end of the cable connects to the printer connector at the host computer. 



PIN NO. 


PARALLEL CONNECTOR PINOUT 


1 


nStrobe/Host Clk 


2-9 


Data Bits 1-8 


10 


nAck/PtrClk 


11 


Busy/Per Busy 


12 


PError/Ack Data Req. 


13 


Select/Xflag 


14 


nAuto Fd/Host Busy 


15 


Not Used 


16-17 


Ground 


18 


+5V@ 1A 


19-30 


Ground 


31 


nlnit 


32 


nFault/nData Avail. 


33-34 


Not Used 


35 


+5Vthru3.3Kfi Resistor 


36 


nSelectln/1 284 active 



Table 12. Rear Panel Parallel Data Connector Pinout 



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Appendix C 




AC Power Cord 

Since many areas of the world have specific power requirements, an 
AC Power Cord may not be included with your printer. Refer to Figure 
30. A power cord must be provided by you that meets your local elec- 
trical requirements. 

WARNING!! For personnel and equipment safety, always use 
a three-prong plug with an earth ground connection to the 
AC Power Source. 

AC Power Cord Specifications 

■ The overall length must be less than 9.8ft. (3.0 meters) 

■ It must be rated for at least 5A, 250V. 

■ The chassis ground (earth) MUST be connected to assure safety and 
reduce electromagnetic interference. The ground connection is 
handled by the third wire (earth) in the power cord. 

■ The AC power plug and IEC320 connector must bear the 
certification mark of at least one of the known international safety 
organizations shown in Figure 30. 



AC POWER 

PLUG FOR 

YOUR COUNTRY 



3 CONDUCTOR 
<HAR> CABLE 



3SI 



I EC 320 
CONNECTOR 



CONTACT 
VIEW 



NEUTRAL 

EARTH 

LIVE 



SQ@^8®<0)(8XB)K 



'EMA 
,EUR 



ICEBECl 



(D@^(g)©^P 



Figure 30. AC Power Cord Requirements 



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Fuse Replacement 

A user-replaceable AC Power Fuse is located just below the AC Power 
Switch at the rear of the printer. The replacement fuse is a 3 AG Fast 
Blow style rated at 5 Amp/250 VAC 

Before replacing the fuse, turn the AC Power Switch OFF and unplug 
the AC Power Cable. 

To replace the fuse, insert the tip of a flatblade screwdriver into the slot 
in the end of the Fuse Holder End Cap. Press in slightly on the End Cap 
and turn the screwdriver slightly counterclockwise. This will disengage 
the End Cap from the Fuse Holder and permit removal of the fuse. 

To install a new fuse, reverse the sequence. 

Shipping 

To ship the Z Series™ printer, remove all ribbon and media from the 
supply and take-up spindles to prevent damage to the printer. Carefully 
pack the printer in a suitable container to avoid damage during transit. 
Whenever possible, use the original "carton within a carton" packing 
materials from the factory. A shipping container can be purchased from 
Zebra Technologies Corporation if the original packaging is lost or de- 
stroyed. 

If you use a different container, package the printer carefully to avoid 
damage. 

CAUTION: When packaging the printer in a rigid container, use 
shock mounts or shock-absorbing packing material. 



Setting Darkness For "In-Spec" Bar Codes 

All Direct Thermal and Thermal Transfer materials do not have the 
same Darkness requirements. The best way to check for the proper 
darkness setting is to use a Bar Code Verifier that actually measures 
bars/spaces and will calculate the PCS ratio. Without the assistance of a 
verifier, your eyes and/or the scanner to be used in the system, are the 
best bet for picking the optimum darkness setting. The following is a 
simple yet effective method for adjusting the darkness setting to print 
"In Spec" bar codes. Refer to Figure 31 for sample bar codes. 



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1. Load media (and Ribbon if required) according to the appro- 
priate Media Loading and Ribbon Loading Instructions found 
in this User's Guide. Insure the Print Method is appropriately 
characterized for either Direct Thermal or Thermal Transfer. 

2. To print a label for evaluation, use the following procedure: 

A. With Power OFF, press and hold the FEED Key. 

B. Turn the Printer Power ON, then release the FEED 
Key. 

C. The Printer will power up and begin printing test la- 
bels. 

3. Print a label, then press the PAUSE Key. The label will con- 
tain two bar codes as well as other printer information. Nor- 
mal bar codes are printed in a horizontal format as they feed 
out of the printer. Rotated bar codes are printed in a vertical 
format. 

4. Compare the test label printed, to the bar codes in Figure 3 1 . 

If the test label appears too light or too dark, refer to Appen- 
dix A and increase or decrease the DARKNESS Setting ac- 
cordingly. 

5. Resume printing by pressing the PAUSE Key again. Print a 
few labels at the new setting and verify that proper "In Spec" 
bar codes are being printed. Repeat steps 3, 4 and 5 until sat- 
isfied. 

6. To terminate the printing of the test labels, press the PAUSE 
Key, then epress the CANCEL Key. 



Printing Conditions 

Too Dark - Dark labels are fairly obvious. The normal bar code bars 
increase in size, and the openings in small alphanumeric characters may 
fill in with ink. It may be readable but not "In Spec". Rotated bar code 
bars and spaces will run together. 

Slightly Dark - Slightly dark labels are not as obvious. The normal 
bar code will be "In Spec". Small character alphanumerics will be bold 
and could be slightly filled in. The rotated bar code spaces are small 
when compared to the "In Spec" code, possibly making the code un- 
readable. 



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Slightly Light - Slightly light labels are, in some cases, preferred to 
slightly dark for "In Spec" bar codes. Both normal and rotated bar 
codes will be "In Spec", but small alphanumeric characters may not be 
complete. 

Too Light - Light labels are very obvious. Both normal and rotated 
bar codes have incomplete bars and spaces. Small alphanumeric char- 
acters are unreadable. 

In Spec - The "In Spec" bar code can only be confirmed by a verifier, 
but it should exhibit some very visible characteristics. The normal bar 
code will have complete, even bars and clear, distinct spaces. The ro- 
tated bar code will also have complete bars and clear distinct spaces. 
Although it may not look as good as a slightly dark bar code, it will be 
"In Spec". In both normal and rotated styles, small alphanumeric char- 
acters will look complete. 



ROTATED BAR CODES 







| TOO LIGHT 

SLIGHTLY LIGHT 


IN SPEC 




SLIGHTL 


V DARK 



III! I! Illl II!! II II 



TOO DARK 



«CODE-3S« 




Figure 31. Bar Code Examples 



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ASCII Code Chart 

American Standard Code for Information Interchange 



HEX 


CHAR 




HEX 


CHAR 




HEX 


CHAR 




HEX 


CHAR 


00 


NUL 


20 


space 


40 


@ 


60 


' 


01 


SOH 


21 


! 


41 


A 


61 


a 


02 


STX 


22 


" 


42 


B 


62 


b 


03 


ETX 


23 


# 


43 


C 


63 


c 


04 


EOT 


24 


$ 


44 


D 


64 


d 


05 


ENQ 


25 


% 


45 


E 


65 


e 


06 


ACK 


26 


& 


46 


F 


66 


f 


07 


BEL 


27 


' 


47 


G 


67 


g 


08 


BS 


28 


( 


48 


H 


68 


h 


09 


HT 


29 


) 


49 


I 


69 


i 


0A 


LF 


2A 


* 


4A 


J 


6A 


i 


0B 


VT 


2B 


+ 


4B 


K 


6B 


k 


OC 


FF 


2C 




4C 


L 


6C 


I 


0D 


CR 


2D 


- 


4D 


M 


6D 


m 


0E 


SO 


2E 




4E 


N 


6E 


n 


OF 


SI 


2F 


/ 


4F 


O 


6F 





10 


DLE 


30 





50 


P 


70 


P 


11 


DC1 


31 


1 


51 


Q 


71 


q 


12 


DC2 


32 


2 


52 


R 


72 


r 


13 


DC3 


33 


3 


53 


S 


73 


s 


14 


DC4 


34 


4 


54 


T 


74 


t 


15 


NAK 


35 


5 


55 


U 


75 


u 


16 


SYN 


36 


6 


56 


V 


76 


V 


17 


ETB 


37 


7 


57 


w 


77 


w 


18 


CAN 


38 


8 


58 


X 


78 


X 


19 


EM 


39 


9 


59 


Y 


79 


y 


1A 


SUB 


3A 




5A 


z 


7A 


z 


1B 


ESC 


3B 




5B 


[ 


7B 


{ 


1C 


FS 


3C 


< 


5C 


\ 


7C 


I 


1D 


GS 


3D 


= 


5D 


l 


7D 


} 


1E 


RS 


3E 


> 


5E 


A 


7E 




1F 


US 


3F 


? 


5F 




7F 


DEL 



NOTE: NOT recommended for use as a Command 

Prefix, Format Prefix, or Delimiter Character 



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Glossary 



alphanumeric Indicating letters, numerals, and characters such as 
punctuation marks. 

backfeed When the printer pulls the media and ribbon (if used) back- 
ward into the printer so that the beginning of the label to be printed 
is properly positioned behind the printhead. Backfeed occurs when 
operating the printer in tear-off, peel-off, or cutter mode. 

bar code A code by which alphanumeric characters can be represented 
by a series of adjacent stripes of different widths. Many different 
code schemes exist, such as the universal product code (UPC) or 
Code 39. 

calibration (of a printer) A process in which the printer determines 
some basic information needed to print accurately with a particular 
media and ribbon combination. To do this, the printer feeds some 
media and ribbon (if used) through the printer and senses whether 
to use the direct thermal or thermal transfer print method,and (if 
using non-continuous media) the length of individual labels or 
tags. 

character set The set of all letters, numerals, punctuation marks, 
and other characters that can be expressed by a particular font or 
barcode. 

check digit A character added to a barcode symbol that indicates to 
the scanner that it has read the symbol correctly. 

continuous media Label or tagstock media that has no notch, gap, or 
web (backing material only) to separate the labels or tags - the 
media is one long piece of material. 

core diameter The inside diameter of the cardboard core at the center 
of a roll of media or ribbon. 

cutter A device that can cut the media into individual labels or tags 
immediately after it is printed. 



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diagnostics Information about which printer functions are not working 
- used for troubleshooting printer problems. 

die-cut labels See non-continuous media. 

direct thermal A printing method in which the printhead presses 

directly against the media. Heating the printhead elements causes a 
discoloration of the heat-sensitive coating on the media. By selec- 
tively heating the printhead elements as the media moves past, an 
image is printed onto the media. No ribbon is used with this print- 
ing method. Contrast this with thermal transfer. 

direct thermal media Media that is coated with a substance which 
reacts to the application of direct heat from the printhead to 
produce an image. 

fanfold media Media that comes folded in a rectangular stack. 
Contrast this with roll media. 

font A complete set of alphanumeric characters in one style of type. 
Ex: CG Times™, CG Triumvirate Bold Condensed™. 

ips "inches-per-second" The speed at which the label or tag is 

printed. Zebra offers printers that can print from 2 ips to 12 ips. 

label An adhesive-backed piece of paper, plastic, or other material on 
which information is printed. 

label available sensor For printers equipped with the Peel-Off Option, 
this sensor detects a printed label waiting to be taken or "picked" 
by the operator. While it detects this label, the printer will not print 
additional labels. Once the label has been removed from the 
printer,the next label is printed. Also called the "take-label sensor". 

label backing (label liner) The material on which labels are affixed 
during manufacture and which is discarded or recycled by the 
end-users. 

media Material onto which data is printed by the printer. Types of 
media include: tagstock, die-cut labels, continuous (with and with- 
out backing material), fanfold, and roll. 

media sensor This sensor is located behind the printhead to detect the 
presence of media and, for non-continuous media, the position of 
the web, hole, or notch used to indicate the start of each label. 

media supply hanger The stationary arm that supports the media roll. 



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non-continuous media Consumable printing stock which contains an 
indication of where one label/printed format ends and the next one 
begins. Examples are die-cut labels, notched tagstock, and stock 
with black mark registration marks 

non-volatile memory Electronic memory that retains data even when 
the power to the printer is turned OFF. 

print speed The speed at which printing occurs. For thermal transfer 
printers, this speed is expressed in terms of ips (inches per second). 
Zebra offers printers that can print from 2 ips to 12 ips. 

printhead wear The degradation of the surface of the printhead and/or 
the print elements over time. Heat and abrasion can cause print- 
head wear. Therefore, to maximize the life of the printhead, use the 
lowest print darkness setting (sometimes called burn temperature 
or head temperature) and the lowest printhead pressure necessary 
to produce good print quality. In the thermal transfer printing 
method, use ribbon that is as wide or wider than the media, to 
protect the printhead from the rough media surface. 

registration Alignment of printing with respect to the top of a label or 
tag. 

ribbon A band of material consisting of a base film coated with wax 
or resin "ink". The inked side of the material is pressed by the 
printhead against the media. The ribbon transfers ink onto the 
media when heated by the small elements within the printhead. 
Zebra ribbons have a coating on the back that protects the print- 
head from wear. 

ribbon wrinkle A wrinkling of the ribbon caused by improper align- 
ment or improper printhead pressure. This wrinkle can cause voids 
in the print and/or the used ribbon to rewind unevenly. This condi- 
tion should be corrected by performing adjustment procedures. 

roll media Media that comes supplied rolled onto a core (usually card- 
board). Contrast this with fanfold media. 

supplies A general term for media and ribbon. 

tag A type of media having no adhesive backing but featuring a hole 
or notch by which the tag can be hung on something. Tags are usu- 
ally made of cardboard or other durable material. 



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take label sensor See label available sensor. 

thermal direct See direct thermal. 

thermal transfer A printing method in which the printhead presses 
an ink or resin coated ribbon against the media. Heating the print- 
head elements causes the ink or resin to transfer onto the media. 
By selectively heating the printhead elements as the media and 
ribbon move past, an image is printed onto the media. Contrast this 
with direct thermal. 

void A space where printing should have occurred, but did not due to 
an error condition such as wrinkled ribbon or faulty print elements. 
A void can cause a printed bar code symbol to be read incorrectly 
or not at all. 



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Index 



A 

AC Power 2 

Adjustments 

Media Sensor Position 9 
Printhead Pressure 24 

ASCII Control Codes 
XOFF(DC3) 71 
XON(DCl) 71 

c 

Calibration 17 

Caution 

Ribbon Width 8 
Shipping 74 
Unshielded Cables 71 

CCITTV.24 71 

Cleaning 19 

Cutter Module 22 
Platen 20 
Printhead 20 

Recommended Schedule 19 
Sensors 20 

Communication Interfaces 69 
IEEE 1284 Parallel 72 
RS-232 Serial 70 
RS-485 Serial 71 

Communications 2 

Configuration 55 

Factory Settings 3, 4 

Configuration Label 39 



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D 

Damage Report 1 
DIP Switches 55 
DTR (Data Terminal Ready) 71 

E 

EIARS232 71 

Electrical Noise 69 

Error Conditions 46 
LCD Display 27 

F 

Factory Defaults 44 

FCC Rules and Regulations 71 

Front Panel 

Deluxe 27, 59 
Standard 55 

Front Panel Control Keys 58 

Front Panel Keys 13 

Front Panel LEDs 14 

Fuse Replacement 73 

G 

Glossary 79 

I 

IN SPEC Bar Codes 74 

Initialization 

Flash Memory 45 
PCMCIA Card 45 

L 

Liquid Crystal Display 13, 27 

Loading 
Media 5 
Ribbon 7 

Lubrication 24 



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M 

Maintenance 1 

Media 

Continuous 9 
Fanfold 6 
Non-Continuous 9 
Roll 6 

Media Alignment 
Power Peel 25 
Power Rewind 25 

Media Guide 6, 29, 31, 32 

Media Loading 5 

Media Sensor 
Operation 9 
Position 9 

Media Sensors 9 

Media Supply Guide 6, 29, 31, 32 

Media Supply Hanger 6, 29, 31, 32 

o 

Optional Fonts 53 

Options 

Communication 33 
Cutter 31 

DRAM Memory 33 
Flash Memory 33 
PCMCIA Memory Card 33 
Power Peel 28 
Power Rewind 28 
Value Peel 30 

P 

Power ON Self Test 35 

Printer Configuration 59 

Printer Configuration Label 39 

Printer Options 28 

Printer Power 2 

Printer Specifications 47, 48 

Printhead Pressure 24 



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R 

Reporting Damage 1 

Ribbon Loading 7 

Ribbon Removal 8 

Ribbon Supply Spindle 8 

Ribbon Takeup Spindle 8 

RS-232 70 

Chassis Ground 69 
DSR (Data Set Ready) 69 
DTR (Data Terminal Ready) 69 
RTS (Request To Send) 69 
RXD (Receive Data) 69 
Signal Ground 69 
TXD (Transmit Data) 69 

RS-485 71 

InputA(+) 69 
Input B (-) 69 
Output A (+) 69 
Output B(-) 69 
Signal Ground 69 

RTS (Request To Send) 71 

Self-Test Labels 38 

Self-Tests 

Power ON 35 
Printer 38 

Sensor Positioning 9 

Settings 

Communicaitons 56 

Darkness 58 

Operating Modes 57 

Print Darkness 58 
Shipping 74 
Shipping Container 74 
Shipping Damage 1 
Specifications 48 
Standard Fonts 5 1 
Storage and Reshipping 71 
Switch Settings 55 

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T 

Troubleshooting 35 

u 

Unpacking 1 

w 

Warning 

AC Power 2, 73 
Earth Ground 2, 73 
Equipment Safety 2, 73 
Personnel Safety 2, 73 

z 

ZPLII 1, 17, 50 

ZPL II Instructions 

Changing Prefixes & Delimiters ( A CC, A CD, A CT) 37 
Configuration Update ( A JUS) 44 
Label Length ( A LL) 9 



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